Lightweight Panel Edge Support With Ultrasonic Thermoplastic Anchoring
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Solution Overview
Problem
Existing methods for attaching edges to lightweight panels are either heavy, require significant effort, or are complex and unsuitable for non-industrial production, particularly for creating visually appealing finishes in ready-to-assemble or custom-made goods.
Innovation Solution
A method using a thermoplastic edge support anchored into both cover layers of the panel through mechanical vibrations, causing the thermoplastic material to liquefy and form a secure, form-fitting bond with the wood material, allowing for easy attachment of edges without extensive machinery or preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional bolts are used to attach edges, then mechanical stability is improved, but weight increases significantly and attachment effort increases
Solution Approach 1:
The patent changes the physical state of the thermoplastic material from solid to liquid through ultrasonic vibration-induced melting, enabling it to flow into the cover layers and form strong anchors. This parameter change allows the material to achieve high bonding strength without the weight penalty of traditional bolts.
Solution Approach 2:
The thermoplastic material undergoes a phase transition from solid to liquid state during the bonding process through ultrasonic vibration. This phase transition enables the material to penetrate and bond with the cover layers, then solidifies to create a strong, lightweight anchor that replaces heavy metal bolts.
2Ease of manufacture
If supporting edges are used for edge attachment, then ease of manufacture is improved, but device complexity increases and suitability for non-industrial production deteriorates
Solution Approach 1:
The patent replaces complex mechanical milling and attachment systems with a simpler ultrasonic vibration-based thermoplastic bonding system. This substitution eliminates the need for specialized supporting edge machinery while achieving comparable or superior bonding results, making the process suitable for both industrial and non-industrial production.
Solution Approach 2:
The thermoplastic material itself performs the anchoring function through its own phase transition and flow characteristics when subjected to ultrasonic vibration. The material self-adapts to the cover layer geometry and self-anchors without requiring pre-milled recesses or specialized fixtures, simplifying the overall manufacturing process.
3Weight of moving object
If thermoplastic edge support with ultrasonic vibration is used, then weight is reduced and ease of manufacture is improved, but manufacturing precision requirements increase
Solution Approach 1:
Ultrasonic vibration is applied to the thermoplastic material during bonding, causing it to melt and flow into the cover layers. This vibration mechanism provides precise control over the material flow and penetration depth, ensuring consistent anchoring precision while maintaining the lightweight advantage of thermoplastic materials.
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
Enables efficient, lightweight, and visually appealing edge attachment suitable for both industrial and non-industrial production, using inexpensive tools like ultrasonic devices, with minimal depth and no need for pre-treating the panels, maintaining mechanical stability and reducing material waste.
Implementation Method 1
by a from the narrow side (i.e. sonotrode not acting through the cover layers) mechanical vibrations are coupled into the edge support
Implementation Method 2
with the edge support being simultaneously pressed against this cover layer in such a way that in the area of a transition between the thermoplastic material and the wood material of the cover layer, part of the thermoplastic material liquefies
Implementation Method 3
part of the thermoplastic material liquefies and is pressed into the top layer material, which results in a form-fitting anchorage after curing
Implementation Method 4
the liquefaction being brought about by friction with the cover layer and/or internal friction of the thermoplastic material
Data Source
Figure 1a~1c
Figure 1d~3a
Figure 3b~6a
AI summary
According to the invention, the lightweight component is equipped with two cover layers (1.1, 1.2), which are made of a wood material, for example, and a filling disposed in between said layers after cutting everything to size, having an edge support (3) comprising thermoplastic material. This is done in that said edge support is anchored both in the first cover layer and in the second cover layer starting from the narrow side, wherein the anchoring is achieved in that the edge support is brought into contact with the respective cover layer and mechanical vibrations are coupled into the edge support by a sonotrode (5) engaging from the narrow side, wherein the edge support at the same time is pressed against said cover layer such that in the region of a transition between the thermoplastic material and the wood material of the cover layer part of the thermoplastic material is liquefied and pushed into the cover layer material, thereby producing a positively engaged anchoring after hardening. Said method is carried out in a continuous process when using an expanded edge support, or in a repeated process when using a plurality of edge supports, until an expanded region of the narrow side is provided with the edge support or the edge supports. In addition, an edge is fastened to the edge support or the edge supports such that the intermediate space between the cover layers is closed toward the narrow side in said expanded region.