Portable Composite Panel Structure for Lightweight Waterproof Assembly

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional methods for constructing portable panels result in heavy, water-susceptible, and labor-intensive products with adhesive failures, lacking in lightweight durability and cost-effectiveness for broad market accessibility.

Innovation Solution

A portable panel construction method using a lightweight core with impregnated polyurethane layers and external skins, bonded through polyurethane polymerization, eliminating the need for molds and incorporating a lateral movement suppression system for secure panel interconnection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional methods use oriented strand board or plywood with manual adhesive application, then the panel structure is established, but the panels become heavy and water-susceptible with labor-intensive production

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidpanel weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent changes the physical and chemical parameters of the bonding process by using polyurethane components that react and cure in place, eliminating the need for traditional adhesives. This chemical parameter change enables lightweight core materials to be used without compromising structural integrity

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite material construction with a lightweight core (such as honeycomb structure) combined with polyurethane layers that are impregnated with reactive components. This composite approach maintains structural strength while significantly reducing weight compared to conventional solid wood or particle board

Inventive Principle:

Principle #40Composite materials

2Strength

If conventional methods use manual adhesive application and pressing, then the layers are bonded, but the process becomes labor-intensive and time-consuming

Engineering Contradiction:

Improveadhesion strengthVSAvoidproduction efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent implements self-service bonding where the polyurethane components automatically react and cure without requiring manual adhesive application or external pressing equipment. The reactive components self-bond the layers together through chemical reaction, eliminating labor-intensive steps while maintaining strong adhesion

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent replaces the mechanical adhesive application and pressing system with a chemical reaction system. Instead of using mechanical force to bond layers with adhesives, the polyurethane components undergo chemical polymerization to create strong bonds, substituting mechanical processes with chemical processes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If conventional methods use traditional construction approaches, then the panels are durable, but they remain susceptible to water damage

Engineering Contradiction:

Improvestructural durabilityVSAvoidwater susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent uses polyurethane layers that form a protective flexible film over the lightweight core structure. This polyurethane skin acts as a water-resistant barrier while maintaining the overall structural durability, protecting the core from water damage without compromising strength

Inventive Principle:

Principle #30Flexible shells and thin films

4Manufacturing precision

If conventional methods use molds for construction, then the panels achieve precise dimensions, but the production costs increase

Engineering Contradiction:

Improvedimensional accuracyVSAvoidproduction cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-impregnating the polyurethane layers with reactive components before assembly. This preliminary preparation allows the panels to cure and bond precisely without requiring expensive molds during the bonding process, achieving dimensional accuracy while reducing production costs

Inventive Principle:

Principle #10Preliminary action

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 waterproof, lightweight panels with superior adhesion and durability, reducing production costs and assembly time, while preventing panel movement and enhancing safety with thinner profiles and improved wear resistance.

Implementation Method 1

A first polyurethane layer is impregnated in the first fiber layer while a second polyurethane layer is impregnated into the second fiber layer. Each of these steps can take place individually then the composite is placed into a press for a cure cycle.

Methodology Applied

Scientific EffectCuring process: Photopolymerisation

Data Source

PatentUS20090211499A1Portable Panel Construction And Method For Making The Same

Publication Date: 2009.08.27 PS FURNITURE

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.