Reinforced Multilayer Panel Insertion Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing multilayer panels in the transport sector, such as in nautical and aviation applications, face issues with material weakening, manual insertion of structural reinforcements, and increased error probability, leading to reduced efficiency and increased costs due to the need for manual operations and material removal, which compromises the panel's structural integrity and performance.
Innovation Solution
A method and machine that allow the insertion of reinforcing elements into the filling layer before coupling the upper coating layer, ensuring a secure grip and containment within the panel, while minimizing material removal from the coating layers, enabling automatic positioning and processing to enhance structural resistance and reduce manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If material removal (milling) is performed on the preformed panel to insert structural reinforcement, then the reinforcement can be inserted into the panel, but the entire structure of the multilayer panel is weakened
Solution Approach 1:
The method performs preliminary actions by first removing material from the filling layer to create a seat, then inserting the reinforcement element, and finally coupling the upper coating layer over the reinforcement. This sequence ensures the reinforcement is embedded within the panel structure before final assembly, providing structural strength without requiring weakening of the outer skin through subsequent operations.
Solution Approach 2:
The panel structure is segmented into distinct functional layers: the filling layer serves as the structural base for reinforcement insertion, while the upper coating layer provides protective and aesthetic functions. This segmentation allows the filling layer to be modified for reinforcement insertion without compromising the integrity of the upper coating layer.
2Ease of operation
If manual insertion of reinforcement inserts is used, then the reinforcement can be positioned in the panel, but the speed of the producing process is reduced and error probability increases
Solution Approach 1:
The method enables self-service by designing the reinforcement insertion process to be inherently stable and self-aligning. The seat created in the filling layer provides natural positioning for the reinforcement element, and the subsequent coupling of the upper coating layer secures the reinforcement without requiring manual adjustment or intervention, thereby reducing errors and increasing productivity.
3Ease of manufacture
If structural reinforcement is inserted after milling and removing material, then the reinforcement can be placed in the seat, but the reinforcement is easily removable following tensile or tearing stress
Solution Approach 1:
The upper coating layer is coupled to the filling layer in advance, covering and securing the reinforcement element before final panel assembly. This preliminary action ensures the reinforcement is permanently embedded within the panel structure, providing resistance to tensile and tearing stresses that would otherwise allow easy removal of the reinforcement.
4Shape
If a finishing layer of small thickness is applied over the insert, then the panel aesthetics are improved, but the insert coverage is very fragile with respect to tensile or tearing stresses
Solution Approach 1:
The panel structure is segmented into functional layers where the upper coating layer serves as both a structural element and a protective covering for the reinforcement. This segmentation provides substantial thickness and strength to the coverage, eliminating the fragility associated with thin finishing layers while maintaining aesthetic quality.
Data Source
Figure 1(A)~2
Figure 3(a)~4
Figure 5~6
AI summary
The present invention relates to a method for manufacturing a reinforced multilayer panel, arranged on a panel processing machine, wherein the multilayer panel has a substantially planar filling layer (50), a first coating layer (30) coupled to a first face of the filling layer (50), and a second coating layer (70) coupled to a second face of the filling layer (50), said method comprising the steps of: placing at least one filling layer (50) on a support surface of a panel processing machine; remove a portion of said filling layer (50) to obtain a seat (18) for housing a reinforcing element (80); housing a reinforcing element (80) in said seat (18); coupling a second coating layer (70) to an upper face of said filling layer (50); removing a portion of said second coating layer (70) at said reinforcement element (80), so as to allow access to said reinforcement element (80) from a position external to the panel.