Multiwall Sheet Segmentation for Rigidity and Volume Trade-off
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Solution Overview
Problem
Multiwall sheets face challenges in achieving high flexural rigidity while minimizing volume for transportation and storage, and require complex assembly and additional structural reinforcements, which increase manufacturing time and cost.
Innovation Solution
A multiwall sheet design that can be extruded as a single unit, collapsed for transportation, and expanded on-site to desired thickness, featuring deformable ribs and a locking mechanism, allowing for customizable thickness and volume with filler materials for enhanced structural and thermal performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of the multiwall sheet is increased to increase flexural rigidity, then the flexural rigidity is improved, but the volume increases making transportation and storage difficult
Solution Approach 1:
The multiwall sheet is divided into multiple walls (first wall, second wall, third wall) separated by intermediate walls and cavities. This segmentation allows the sheet to achieve high flexural rigidity through the multi-wall structure rather than increasing overall thickness, enabling compact transportation while maintaining structural strength.
Solution Approach 2:
The patent transitions from a single thick wall structure to a multi-dimensional multiwall structure with intermediate walls and cavities arranged in specific patterns. This dimensional reorganization provides enhanced flexural rigidity without proportionally increasing volume, as the rigidity comes from the structural arrangement rather than material quantity.
2Volume of moving object
If multiwall sheets are assembled on-site to reduce transportation volume, then the volume for transportation is reduced, but complex machinery and assembly processes are required
Solution Approach 1:
The multiwall sheet is manufactured as a single integrated unit with all walls, intermediate walls, and cavities formed together in one extrusion process. This merging eliminates the need for complex on-site assembly of multiple separate components, reducing both assembly complexity and the machinery required while maintaining the space-efficient multiwall structure.
3Reliability
If structural reinforcements are added to prevent inter-laminar detachment, then the reliability is improved, but manufacturing time and cost increase
Solution Approach 1:
The intermediate walls are fully integrated into the multiwall structure during the single-step extrusion process, forming continuous structural elements that prevent inter-laminar detachment. This integration eliminates the need for separate reinforcement components and additional manufacturing steps, maintaining high reliability while minimizing manufacturing time and cost.
Data Source
Figure 1
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Figure 3~3A
AI summary
In one embodiment, a multiwall sheet can comprise: a first wall; a second wall; an intermediate wall disposed between the first wall and the second wall; a first set of ribs disposed between the first wall and the intermediate wall; a second set of ribs disposed between the second wall and the intermediate wall; a cavity disposed between adjacent ribs; wherein the multiwall sheet is configured to expand and/or collapse when a mechanical force (preferably shear force) is applied to the intermediate wall. Preferably the multiwall sheet has a flexural rigidity of greater than or equal to 10 N/mm.