Multilayered Injection Molded Wicker-Like Panel
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Solution Overview
Problem
Current methods for creating injection molded articles that mimic the appearance of woven panels, such as wickerwork, lack the ability to achieve a true three-dimensional interlaced structure with adequate flexibility and uniform material flow during the molding process.
Innovation Solution
A multilayered injection molding process involving a base layer and two exterior layers with bulging portions exposed through openings, interconnected by ribs, allowing for the flow of molten material and creating a wicker-like pattern, with the option of using different materials and properties for each layer to enhance flexibility and appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a multilayered injection molding process is used to create three-dimensional interlaced structure, then the appearance and structural accuracy of woven panel is improved, but the device complexity and manufacturing process complexity increases
Solution Approach 1:
The panel is divided into multiple layers (base layer, first exterior layer, second exterior layer) with each layer having specific functions. The base layer provides structural support while exterior layers provide surface appearance and flexibility. This segmentation allows complex three-dimensional interlaced structures to be achieved through controlled material flow in each layer during injection molding.
Solution Approach 2:
The patent transitions from traditional two-dimensional flat panels to three-dimensional interlaced structures by adding vertical dimension through bulging portions that protrude from the panel surface. These bulges create the woven appearance effect and enable light transmission through apertures, achieving visual complexity through dimensional enhancement rather than traditional multi-component assembly.
2Adaptability or versatility
If different materials are used for base layer and exterior layers to enhance flexibility and appearance, then the aesthetic appeal and flexibility are improved, but the manufacturing precision and material adhesion requirements increase
Solution Approach 1:
Different regions of the panel have different material properties optimized for their specific functions. The base layer uses materials providing structural integrity and dimensional stability, while exterior layers use materials providing surface appearance, flexibility, and tactile qualities. This local differentiation allows each layer to be optimized independently while maintaining overall panel performance.
Solution Approach 2:
The panel employs composite construction with multiple material layers, each selected for its specific properties. The base layer and exterior layers can be made from different polymers or material compositions that are compatible with injection molding processes but have distinct mechanical and aesthetic characteristics, creating a composite structure that combines advantages of individual materials.
3Shape
If apertures are created through the layers to expose bulging portions, then the visual appearance of woven pattern is improved, but the structural integrity and material distribution uniformity may be compromised
Solution Approach 1:
The panel incorporates apertures through the layers to expose bulging portions, creating a porous or open structure that enables light transmission and visual penetration. This allows the woven pattern appearance to be achieved while maintaining structural integrity through the base layer and exterior layer framework that surrounds and supports these aperture regions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The process enables the production of injection molded panels and articles that resemble woven panels with a true three-dimensional interlaced structure, offering flexibility and uniform material distribution, suitable for various applications like furniture, while maintaining the aesthetic appeal of woven materials.
Implementation Method 1
the bulging portions of the first exterior layer and the second exterior layer are interconnected through ribs facilitating flow of molten material during an injection molding process
Data Source
Figure 1A
Figure 1B
Figure 1C~1E
AI summary
The disclosed subject matter pertains to a panel, an article comprising such a panel and method of its manufacture, where the panel comprises a base layer having a first face and a second face, integrally sandwiched between a first exterior layer applied over the first face, and a second exterior layer applied over the second face. In addiction, the bulging portions of the base layer projecting from the first face and the second face are exposed through respective openings at the first exterior layer and the second exterior layer, extending in register with said bulging portions.