Polypropylene Separation Panel with Welded Cavities
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Solution Overview
Problem
Existing separation panels for animal enclosures lack mechanical strength, hygiene, and thermal insulation, and are prone to damage from high-pressure cleaning and fire, while also being difficult to clean and maintain.
Innovation Solution
A method of manufacturing separation panels using injection-molded semi-panels with connected inside cavities, which are welded together to form a closed structure, providing improved mechanical strength and hygiene, and can be filled with fire-resistant materials for enhanced thermal insulation and fire resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If separation panels are made from laminated fibreboard to achieve light weight, then ease of manual movement is improved, but water resistance and hygiene are worsened as the material absorbs humidity and swells
Solution Approach 1:
The patent uses polypropylene, a synthetic polymer material that combines light weight with excellent water resistance and hygiene properties. The material is resistant to humidity absorption, swelling, and degradation from cleaning agents, resolving the contradiction between light weight and water resistance.
2Strength
If separation panels are made from concrete to improve mechanical strength and fire resistance, then strength and fire resistance are improved, but weight increases and hygiene requires additional coating
Solution Approach 1:
The patent employs polypropylene, a synthetic material that provides sufficient mechanical strength for animal enclosure applications while maintaining light weight. The material's inherent resistance to cleaning agents and moisture eliminates the need for additional hygienic coatings required by concrete panels.
3Strength
If separation panels use steel reinforcement to improve mechanical strength, then strength is improved, but weight increases and hygiene is worsened due to rusting
Solution Approach 1:
The patent uses polypropylene, a corrosion-resistant synthetic polymer that provides the necessary mechanical strength without the rusting problems of steel reinforcement. The material maintains its structural integrity and hygiene properties throughout its service life in humid, chemically aggressive environments.
4Reliability
If separation panels have smooth convex outer surfaces to prevent dirt accumulation and animal injury, then hygiene and safety are improved, but mechanical strength may be reduced
Solution Approach 1:
The patent uses polypropylene with appropriate thickness and structural design to achieve both smooth convex surfaces for hygiene and safety, and sufficient mechanical strength. The material's inherent properties allow for design flexibility that maintains both surface quality and structural integrity.
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
The solution enhances the mechanical strength and hygiene of separation panels, allowing them to withstand high-pressure cleaning and fire, while also providing effective thermal insulation and ease of cleaning, making them suitable for animal enclosures and construction applications.
Implementation Method 1
producing two semi-panels by injection moulding using the mould
Implementation Method 2
welding the two semi-panels together along the longitudinal walls and the traverse walls
Data Source
Figure 1
Figure 2A~2F
Figure 3
AI summary
A method of manufacturing a separation panel (1) comprising: - producing by injection moulding two semi-panels (101;102) comprising: ⋅ a sidewall (110) comprising an inner surface (111) and an outer surface (112); ⋅ a pair of parallel longitudinal walls (120) and/or a pair of parallel traverse walls (130); and wherein at least one semi-panel (101) further comprises a plurality of partition walls (140) delimitating inside cavities (150) in said semi-panel (101), and wherein one or more of said partition walls (140) comprise respective openings (141); - arranging said two semi-panels (101;102) one against the other, thereby forming a structure (2) with a plurality of inside cavities (150) connected through said openings (141); and - welding said two semi-panels (101;102) together, thereby forming said separation panel (1).