Large Sandwich Panel Pressing for Rigidity and Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional multi-layer panels lack structural rigidity and insulation, and existing manufacturing methods struggle to produce large-sized panels with desirable characteristics in a cost-effective manner.
Innovation Solution
The method involves a two-stage process: (A) roll-material preparation, where a rolled material is unrolled, processed, and rolled again, and (B) assembling/heating/pressing, where the processed rolled material is cut, sealed, and pressed with an insulation layer to form a large-sized sandwich panel under a predetermined temperature profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional manufacturing methods are used to produce large-sized panels, then production cost is reduced, but structural rigidity and insulation performance deteriorate
Solution Approach 1:
The manufacturing process is divided into two distinct stages: (A) roll-material preparation stage where materials are processed individually, and (B) assembling/heating/pressing stage where components are combined. This segmentation allows each stage to be optimized independently, enabling large-sized panel production with proper structural rigidity while maintaining cost-effectiveness through efficient resource utilization.
Solution Approach 2:
In the roll-material preparation stage, materials are pre-processed including unrolling, surface treatment, and rolling before assembly. This preliminary action ensures that all materials are properly prepared and positioned, enabling the final assembly stage to focus on creating the sandwich structure with optimal rigidity and insulation properties.
2Temperature
If traditional multi-layer panels are used, then manufacturing simplicity is maintained, but insulation performance and structural rigidity deteriorate
Solution Approach 1:
The patent creates a sandwich panel structure composed of multiple distinct layers including outer panels, insulation layers, and sealant patterns. This composite material approach combines materials with different properties (structural materials for rigidity, insulation materials for thermal performance) to achieve superior overall performance compared to traditional homogeneous multi-layer panels.
Solution Approach 2:
The sandwich panel structure provides different properties at different locations: outer panels provide structural rigidity and protection, while inner insulation layers provide thermal insulation. This local quality differentiation allows the panel to simultaneously achieve high structural rigidity and excellent thermal insulation performance.
3Area of stationary object
If panel size is increased beyond traditional dimensions, then application versatility is improved, but manufacturing capability deteriorates
Solution Approach 1:
The patent transitions from traditional small-sized panels to large-sized panels by fundamentally changing the manufacturing approach. The two-stage process with roll-material preparation followed by assembling/heating/pressing enables production of panels with dimensions around 40 feet×10 feet×2 inches, effectively moving to another dimension of manufacturing capability.
Solution Approach 2:
The patent changes key manufacturing parameters including temperature (heating during pressing), pressure (applying pressure during assembly), and time (predetermined time period for pressing). These parameter changes enable the manufacturing of large-sized panels with proper bonding and structural integrity, overcoming previous manufacturing limitations.
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
This approach enables the production of large-sized sandwich panels with enhanced structural rigidity and thermal insulation, suitable for industrial applications such as stackable trailer systems, while being cost-effective.
Implementation Method 1
pressing the upper flat portion, by an upper large sized mold, against the insulation layer and the bottom flat portion under a predetermined temperature profile during a predetermined time period
Data Source
AI summary
Methods and systems for manufacturing large sized sandwich panels are provided. In some embodiments, the method includes (1) positioning a bottom flat portion or a rolled material on a bottom large sized mold; (2) applying a first sealant in a first predetermined pattern on an upper surface of the bottom flat portion; (3) positioning an insulation layer on the upper surface of the bottom flat portion; (4) applying a second sealant in a second predetermined pattern on an upper side of the insulation layer; (5) positioning a upper flat portion on the upper side of the insulation layer; (6) pressing the upper flat portion, by an upper large sized mold, against the insulation layer and the bottom flat portion under a predetermined temperature profile during a predetermined time period.