Portable Panel Construction with Pinched Edge and Spray Adhesive
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Solution Overview
Problem
Conventional methods for constructing portable panels result in heavy, water-susceptible, and labor-intensive products with inadequate edge protection and sound absorption, lacking portability and storability, and often suffer from glue failure and disfigurement.
Innovation Solution
A lightweight panel construction using a core with fiber layers impregnated with polyurethane and bonded with external skins, featuring a frame with a locking mechanism to prevent lateral movement and a pinched edge design for impact resistance, allowing for easy assembly, disassembly, and stacking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional methods use oriented strand board or plywood with manual glue application, then the panel structure can be assembled, but the panels become heavy, water-susceptible, and labor-intensive with glue failure risks
Solution Approach 1:
The patent replaces manual mechanical glue application with a spray-applied adhesive system that automatically applies adhesive to the core structure. This substitution eliminates manual labor, ensures consistent adhesive coverage, prevents glue failure, and reduces panel weight by optimizing adhesive usage.
Solution Approach 2:
The patent changes the physical state and application method of the adhesive from manual paste application to spray-applied liquid adhesive. This parameter change enables uniform distribution, controlled drying time, and optimized bonding strength while reducing overall adhesive consumption and panel weight.
2Strength
If conventional methods use steel skins with laminate skin and elastomer edging molded around the panel, then edge protection is provided, but the panels become heavy and difficult to transport
Solution Approach 1:
The patent uses composite materials including foam core, fiber layers, polyurethane adhesive, and skin layers to create a lightweight yet durable panel structure. This composite construction provides edge protection and structural strength while significantly reducing weight compared to conventional steel and heavy laminate constructions.
Solution Approach 2:
The patent employs thin skin layers and flexible fiber-polyurethane composites to provide edge protection and structural integrity. These thin films and flexible shells replace heavy steel skins and thick elastomer edging, maintaining durability while reducing panel weight for easier transportation.
3Ease of manufacture
If conventional methods use manual glue application and multi-step assembly, then panels can be constructed, but the process becomes labor-intensive and time-consuming
Solution Approach 1:
The patent replaces manual mechanical assembly operations with automated spray adhesive application and streamlined assembly processes. This substitution eliminates manual labor bottlenecks, ensures consistent adhesive application, and significantly increases production speed while maintaining manufacturing simplicity.
Solution Approach 2:
The patent applies adhesive to the core structure before assembling the skin layers, ensuring proper bonding is established in advance. This preliminary action streamlines the assembly process, eliminates subsequent bonding issues, and increases overall production efficiency by preventing rework.
4Strength
If conventional panels lack specialized edge design, then manufacturing is simpler, but the panels suffer from inadequate edge protection and shock absorption
Solution Approach 1:
The patent creates enhanced edge protection through composite construction combining foam core, fiber layers, and skin layers that work together to provide shock absorption and durability. This composite approach strengthens edges without significantly increasing construction complexity, as the same materials are used throughout the panel structure.
Solution Approach 2:
The patent applies fiber layers and skin layers specifically at the edges and perimeter areas where shock absorption and protection are most needed. This local quality approach concentrates protective materials where required, enhancing edge strength without unnecessarily increasing overall construction complexity or material usage throughout the entire panel.
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 provides a durable, water-resistant, and cost-effective panel that is lighter, easier to transport, and more resistant to edge damage, with improved stacking and storage capabilities, while maintaining stability and sound absorption features.
Implementation Method 1
A first polyurethane layer is impregnated into the first fiber layer while a second polyurethane layer is impregnated into the second fiber layer
Data Source
AI summary
Disclosed herein is a portable panel having numerous favorable characteristics. The panel comprises a core having a length, a width, a first side and a second side. A first fiber layer is attached to the first side while a second fiber layer is attached to the second side. A first polyurethane layer is impregnated in the first fiber layer while a second polyurethane layer is impregnated into the second fiber layer. A first skin is attached to the first polyurethane layer while a second skin is attached to the second polyurethane layer. The panel can be used in the manufacture of tables, flooring, risers, stages, bleachers, and the like.