Partition equipment and its manufacturing method
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Solution Overview
Problem
The high cost of manufacturing molds for large partition equipment and the deterioration of foamable resin over time, leading to design damage and loosening of cover materials, is a challenge in existing panel body forming methods.
Innovation Solution
The use of a cushion material with through holes forming uneven shapes, allowing the cover material to be directly adhered and maintaining the shape through elastic deformation, eliminating the need for molds and enhancing durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a mold is used to form the panel body with unevenness, then the design of the partition equipment is improved, but the manufacturing cost increases significantly
Solution Approach 1:
The patent extracts the mold from the manufacturing process entirely. Instead of using a mold to form the unevenness, the invention uses a cushion material with through-holes that is directly adhered to the base material. The cushion material itself forms the unevenness shape, eliminating the need for expensive mold fabrication and maintenance.
Solution Approach 2:
The cushion material serves as a disposable or replaceable form-giving element. Rather than investing in expensive, long-lasting molds, the patent uses relatively inexpensive cushion material that can be easily replaced if needed, significantly reducing manufacturing costs while still achieving the desired unevenness effect.
2Shape
If foamable resin is used to fill the mold and form the panel body, then the unevenness shape is achieved, but the resin deteriorates over time causing cover material loosening
Solution Approach 1:
The patent removes the foamable resin from the structure entirely. Instead of using resin that deteriorates over time, the invention uses a solid cushion material that is adhered to the base material. This eliminates the deterioration problem while maintaining the unevenness shape-forming function.
Solution Approach 2:
The cushion material with through-holes serves as a physical copy or template for the desired unevenness shape. Rather than using resin that is poured and hardened in a mold, the cushion material itself is the form-giving element that directly creates the unevenness when adhered to the base material, providing a more stable and durable solution.
3Shape
If the cover material is pressed against the mold by foamed resin, then the unevenness is transferred to the panel body surface, but the cover material stretches and becomes loose over time
Solution Approach 1:
The cushion material is pre-formed with the desired unevenness shape and through-holes before being adhered to the base material. This preliminary preparation ensures that the unevenness is already established in the cushion material itself, eliminating the need to stretch the cover material over a mold during the forming process, thereby preventing future loosening.
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 allows for the creation of partition equipment with excellent design at a low cost, maintaining shape stability over time and preventing cover material loosening.
Implementation Method 1
the angle portion of the cushion material is elastically deformed in the direction of compression due to the cover material. Due to this, the formed uneven portion is pressed outward by a repulsive force of the cushion material
Data Source
Figure 1
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AI summary
A panel body (11) includes: an elastic cushion material (13) which is provided at at least a part of a surface of a panel base material (12), and forms an uneven shape having an angle portion (16v) on the surface of the panel base material (12); and a cover material (14) which elastically deforms the angle portion (16v) in the direction of compression, and covers the cushion material (13) and the panel base material (12).