Seamless Panel Manufacturing Using Lattice Trusses
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Solution Overview
Problem
Conventional methods for manufacturing prefabricated modular panels are time-consuming, costly, and complex, as they require custom molds for different lengths and intermediate joints between panel segments, limiting efficiency and increasing production costs.
Innovation Solution
A method of manufacturing seamless panels using a mold with lattice trusses and expandable filler material, allowing for continuous production of panels of any desired length without intermediate joints, by inserting lattice trusses into a mold, filling with filler material, and heating to bond the materials, enabling seamless integration of panel segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional methods use custom molds for different panel lengths, then panels of specific lengths can be produced, but manufacturing cost and device complexity increase due to needing multiple mold sizes in inventory
Solution Approach 1:
A single mold design is used to produce panels of various lengths by controlling the filling process and panel advancement, eliminating the need for multiple custom molds for different panel sizes
Solution Approach 2:
The mold system dynamically adjusts panel production by controlling how much filler material is inserted and how far the panel advances, allowing continuous variation in panel length from the same mold
2Length of moving object
If conventional methods use intermediate joints to connect panel segments, then panels of desired length can be achieved, but structural strength and reliability decrease due to joints and connection points
Solution Approach 1:
The continuous insertion of filler material and sequential advancement of the panel creates a seamless continuous structure without intermediate joints or connection points, maintaining uniform structural integrity throughout the panel length
3Ease of manufacture
If conventional methods prepare and treat panel segment ends before connection, then adjacent segments can be interconnected, but manufacturing time and process complexity increase
Solution Approach 1:
The continuous production process eliminates discrete preparation steps for connecting panel ends, as panels are formed seamlessly without requiring end preparation or post-processing treatment
Solution Approach 2:
The complex end preparation and connection processes are removed entirely from the manufacturing workflow by producing continuous seamless panels that do not require segmentation or joining
4Device complexity
If a single mold is used to produce panels of any length, then manufacturing cost and device complexity decrease, but achieving precise panel lengths and seamless integration becomes more difficult
Solution Approach 1:
The system uses feedback control to monitor panel advancement distance and filler material insertion, adjusting parameters to achieve precise panel lengths and proper integration zones
Solution Approach 2:
The system controls panel length precision by varying parameters such as filler material insertion rate, panel advancement distance, and heating temperature to create proper bonding zones
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 method allows for efficient production of seamless panels of any length using a single mold, reducing production time and costs by eliminating the need for custom molds and intermediate joints, while providing structural rigidity and load-bearing capacity.
Implementation Method 1
heating the mold to bond a portion of the second filler material to a portion of the first filler material remaining in the mold
Implementation Method 2
heating the mold to expand the filler material
Data Source
AI summary
A method is provided for manufacturing a seamless, reinforced panel of any desired length using a single mold. The seamless panels of the present invention may be used in a variety of construction application. In one embodiment, the method includes inserting at least a portion of a plurality of lattice trusses into a mold having an axial length, inserting a first filler material into the mold, the first filler material encapsulating at least a portion of the plurality of lattice trusses to form a panel segment, translating the panel segment a linear distance, the linear distance less than the axial length of the mold such that a portion of the panel segment remains in the mold, and inserting a second filler material into the mold, the second filler material intermixing with the portion of the panel segment remaining in the mold to form a seamless panel.