Lightweight Panel Angled Edge Deformation for Stability
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Solution Overview
Problem
Existing lightweight panels with cellulose material cover layers and a honeycomb middle layer are heavy, necessitating a reduction in weight while maintaining stability and design flexibility.
Innovation Solution
Incorporating foam in the narrow surface area of the panel to eliminate the need for a bar or frame, allowing for deformation of the cover layers to create a stable and impact-resistant edge, which can be individually shaped to form various end configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional frame structures and bar reinforcements are used in lightweight panels, then structural stability and impact resistance are improved, but the overall weight of the panel increases
Solution Approach 1:
The patent removes the heavy frame structure and bar reinforcements from the panel design. Instead of using traditional wooden frames around the edges and bars for reinforcement, the invention relies on the inherent strength of the honeycomb core and the bonding between layers to provide structural stability, thereby significantly reducing the overall weight of the panel.
Solution Approach 2:
The patent employs a composite structure consisting of multiple layers including wood-based panels, particle board, and honeycomb core material bonded together. This composite construction provides structural stability and impact resistance through the combined properties of different materials and their geometric arrangement, eliminating the need for additional heavy reinforcement elements.
2Adaptability or versatility
If cover layers are deformed to create angled end portions, then design flexibility and variety of end configurations are improved, but manufacturing complexity increases
Solution Approach 1:
The patent incorporates strengthening elements (such as additional layers or reinforcement structures) into the cover layers during the initial panel manufacturing process, before any deformation or cutting operations are performed. This preliminary reinforcement ensures that the cover layers have sufficient strength to be deformed into various configurations without breaking, while maintaining relatively simple manufacturing procedures.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 2c
AI summary
The invention relates to a lightweight panel comprising two outer layers (1a, 1b), a central layer (2) situated between the two outer layers (1a, 1b) and a covered narrow face (3) extending from the two outer layers (1a, 1b) across the central layer (2). The aim of the invention is to produce a reinforced edge area more effectively. To achieve this, at least part of the end region (4) of at least one of the outer layers (1a, 1b) runs at an angle to a longitudinal plane (Ea, Eb) of one of said layers (1a,1b). The invention also relates to a corresponding method for producing a lightweight panel.