Single-layer plastic composite board
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Solution Overview
Problem
Current plastic boards for furniture manufacturing are either thick and heavy or require complex processing and high production costs due to the use of multi-layer composite structures, which are not environmentally friendly and inefficient.
Innovation Solution
A single-layer plastic composite board design featuring a bent peripheral portion and a stiffener with a stepped or tubular cross-section, which provides strength and stability while maintaining a simple structure, low cost, and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If single-layer plastic boards are made thick to maintain strength, then strength is improved, but weight and material consumption increase
Solution Approach 1:
The patent combines plastic material with metal stiffeners to create a composite board structure. The metal stiffeners are embedded within or attached to the plastic board, providing enhanced strength and rigidity without requiring the entire board to be thick. This allows the board to maintain high strength while keeping the plastic layer thin and lightweight.
Solution Approach 2:
The board is divided into functional segments: a thin plastic base layer for lightweight properties and embedded metal stiffeners for structural strength. This segmentation allows each component to perform its optimal function - the plastic provides weight reduction while the metal elements provide localized reinforcement where needed.
2Strength
If multi-layer composite plastic boards are used to increase strength, then strength is improved, but processing complexity and production cost increase
Solution Approach 1:
Instead of using multiple plastic layers with different functions, the patent uses a single plastic layer combined with metal stiffeners. This simplifies the processing steps while achieving the same strength enhancement, as the metal stiffeners can be easily embedded or attached during the molding process without requiring complex multi-layer lamination techniques.
3Strength
If multi-layer composite plastic boards are used to increase strength, then strength is improved, but production cost increases
Solution Approach 1:
The combination of plastic and metal stiffeners provides a cost-effective solution because metal stiffeners can be mass-produced and easily integrated into the plastic board during molding. This approach avoids the high costs associated with multi-layer plastic lamination processes, special adhesives, and complex assembly procedures required for traditional composite boards.
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 results in a lightweight, high-strength, and cost-effective single-layer plastic composite board suitable for various applications, including furniture components, with a simple manufacturing process and aesthetically pleasing designs.
Implementation Method 1
a stiffener which is engaged with and fixed to at least a part of the bent portion
Implementation Method 2
the stiffener and the single-layer plastic sheet are fixed to each other via an adhesive, such as glue and the like
Implementation Method 3
or by ultrasonic welding
Data Source
AI summary
A single-layer plastic composite board (20; 30; 40) is disclosed. The single-layer plastic composite board is a two-piece single-layer plastic composite board comprising a single-layer plastic sheet (11; 21) and a stiffener (22; 32), wherein the single-layer plastic sheet (11; 21) has a main body portion (111; 211) and a peripheral portion located around the main body portion; the peripheral portion bends towards the back of the main body portion in a direction perpendicular to the main body portion to form a bent portion (112; 212); and the stiffener (22; 32) is engaged with and fixed to the bent portion (112; 212) of the single-layer plastic sheet (11; 21). The single-layer plastic composite board has advantages such as a simple structure, small thickness, light weight, high strength, low cost and ease of manufacturing, and can be widely used as a cabinet board, a box board, a table board, a drawer board, a seat board and a backrest of a chair, etc.