Panel manufacturing method
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Solution Overview
Problem
The formation of blister-shaped inflation portions at the boundary between the intermediate portion and the hinge in panels manufactured by vacuum forming, due to remaining pressurized air, is a challenge especially when the size of the intermediate portion is small.
Innovation Solution
A method for manufacturing panels that involves extruding first and second resin sheets between molds, shaping them along the mold cavity surfaces, inserting a foamed body between the resin sheets, and closing the molds to form the hinge portion, ensuring that the value of Dg/Ts2 is between 1.5 and 3, where Dg represents the depth of the groove and Ts2 represents the thickness of the second resin sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If vacuum forming is used to manufacture panels with intermediate portions, then production efficiency is improved, but pressurized air remains in the closed space causing blister-shaped inflation portions to form
Solution Approach 1:
The patent introduces a through-hole in the intermediate portion to create a porous structure that allows pressurized air to escape during vacuum forming. This prevents the formation of blister-shaped inflation portions while maintaining production efficiency through vacuum forming methodology.
Solution Approach 2:
The patent extracts the trapped pressurized air from the closed space of the intermediate portion by forming a through-hole. This removal of the harmful element (pressurized air) prevents surface defects while preserving the benefits of vacuum forming production method.
2Manufacturing precision
If the intermediate portion is pierced with a hollow pin to remove pressurized air, then surface quality is improved, but manufacturing complexity increases when the intermediate portion is small
Solution Approach 1:
The patent designs the intermediate portion with a through-hole that automatically allows pressurized air to escape during the vacuum forming process itself. The structure serves its own function of air removal without requiring separate piercing operations or complex molding equipment, especially benefiting small intermediate portions.
3Adaptability or versatility
If the size of the intermediate portion is reduced, then panel design flexibility is improved, but air removal becomes difficult without piercing
Solution Approach 1:
The patent incorporates a through-hole in the intermediate portion structure, creating a porous configuration that enables effective air removal even when the intermediate portion dimensions are reduced. This design feature maintains ease of manufacture across various size scales while preserving design flexibility.
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
This method effectively suppresses the formation of inflation portions at the boundary between the intermediate portion and the hinge, even without piercing the intermediate portion with a hollow pin, by allowing air to escape through the foamed body during molding.
Implementation Method 1
air can easily escape through the foamed body during molding and the pressurized air is suppressed from remaining in the intermediate portion
Implementation Method 2
the hinge portion is formed by sandwiching and compressing the first and second resin sheets and the foamed body between the tip of the ridge and the first mold
Data Source
AI summary
The present invention provides a method for manufacturing a panel by which the formation of a blister-shaped inflation portion at the boundary between an intermediate portion and a hinge can be suppressed, even when the size of the intermediate portion is small. According to the present invention, provided is a method for manufacturing a panel, wherein the panel comprises first and second main body portions, and a hinge portion, the hinge portion comprises first and second hinges extending in parallel and an intermediate portion arranged therebetween, the first main body portion and the intermediate portion are connected by the first hinge so as to be able to pivot relative to each other, the second main body portion and the intermediate portion are connected by the second hinge so as to be able to pivot relative to each other.