Resin Panel Protrusion Structure for Compressive Strength
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Solution Overview
Problem
Conventional resin panels and sandwich panels require enhancement in strength for various applications, particularly in transportation and construction where durability is critical.
Innovation Solution
A method of manufacturing a resin panel by extruding molten resin between split molds with molding protrusions, forming inward protrusions on the panel surfaces, and joining them to create a structure with increased compressive strength, and a sandwich panel comprising these resin panels between skin sheets, with the addition of glass fillers for enhanced rigidity and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional resin panels are used, then manufacturing is simple, but strength is insufficient
Solution Approach 1:
The patent applies curvature by forming protrusions with rounded apical portions instead of flat surfaces. These curved protrusions resist buckling more effectively than flat structures, thereby improving compressive strength while maintaining a relatively simple manufacturing process through extrusion and molding
Solution Approach 2:
The patent implements local quality by creating protrusions with specific geometric features (apical portions and jutting portions) at critical locations on the panel surfaces. These localized structural enhancements provide increased strength where needed without requiring complex overall panel redesign
2Strength
If protrusions are formed on both surfaces to increase strength, then compressive strength improves, but manufacturing complexity increases
Solution Approach 1:
The patent merges the formation of protrusions on both surfaces into a single integrated molding operation. By using a mold with protrusion-forming features that simultaneously shapes both panel surfaces, the manufacturing process achieves enhanced bending strength without requiring separate molding steps, thus avoiding increased manufacturing complexity
3Strength
If a sandwich panel structure is used, then rigidity improves, but weight increases
Solution Approach 1:
The patent applies segmentation by dividing the panel into a core structure with protrusions and separate skin sheets. This segmented architecture provides enhanced rigidity through the protrusion geometry while allowing optimization of each component's material selection and thickness to control overall weight
Solution Approach 2:
The patent uses thin skin sheets as flexible shells that wrap around the protrusion structure. These thin films provide necessary surface coverage and structural integrity while minimizing added weight, achieving high rigidity through the combination of the protrusion core and thin skin layers rather than requiring thick solid panels
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 method results in a resin panel and sandwich panel with improved compressive and bending strength, suitable for demanding applications by creating a structured core with aligned protrusions and jutting portions that resist buckling and bending, thereby increasing overall panel rigidity and strength.
Implementation Method 1
blowing the first molten resin material against the first of the pair of split molds forming a first structure
Implementation Method 2
apical portions of the protrusions of one of the first and second structures abut apical portions of the protrusions of the other of the first and second structures
Data Source
AI summary
A resin panel includes a first structure and a second structure stacked on each other. The structures includes reference surfaces that serve as the front surface and the back surface of the resin panel respectively. Each of the structures includes a plurality of protrusions protruding inwardly from the reference surface. The protrusions of the structure face the protrusions of the other structure each other. Jutting portions of linear shape are formed between adjacent protrusions of each of the structures. The structures are joined such that apical portions of the protrusions of each structure abut one another.