Stacked Mold Sandwich Panel Manufacturing for Large-Scale Output
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Solution Overview
Problem
Traditional methods for manufacturing large-sized metal panels are inefficient, as they lack structural rigidity and insulation, and are not cost-effective for producing panels larger than 5 feet by 5 feet, with the added challenge of only being able to manufacture one panel at a time.
Innovation Solution
A system and apparatus for manufacturing multiple large-sized sandwich panels simultaneously using vertically stackable molds, comprising a surface processing module, an environment management module, a sealant module, and a pressing module, which enables the production of structurally rigid and thermally insulated panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used, then one panel can be manufactured at a time, but the production time and cost increase significantly
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated system where multiple panels are manufactured simultaneously. The pressing module presses multiple sandwich panels at the same time, and the sealant module applies sealants to multiple panels in one operation, thereby merging sequential processes into parallel operations that significantly improve productivity.
Solution Approach 2:
The patent transitions from manufacturing panels in a single layer to stacking molds vertically in multiple layers. This vertical arrangement allows simultaneous manufacturing of multiple panels in the same footprint area, effectively utilizing the vertical dimension to increase production capacity without expanding the horizontal manufacturing space.
2Strength
If traditional multi-layer panels are used, then manufacturing is simpler, but structural rigidity and insulation performance are insufficient
Solution Approach 1:
The patent employs sandwich panel construction consisting of multiple layers including outer skin panels, insulation layers, and sealant layers. This composite structure combines materials with different properties (rigid outer panels for strength, insulating material for thermal performance) to achieve superior overall performance compared to traditional single-material panels.
Solution Approach 2:
The patent applies sealants in specific patterns at critical locations where structural rigidity is needed, rather than uniformly across entire surfaces. The sealant module deposits sealants in predetermined patterns that provide structural support at key joints and connections, optimizing strength while minimizing material usage and complexity.
3Temperature
If traditional multi-layer panels are used, then manufacturing process is simpler, but insulation performance is poor
Solution Approach 1:
The sandwich panel structure incorporates dedicated insulation layers between outer skin panels, creating a composite construction that provides superior thermal insulation. The insulation layer is integrated into the panel manufacturing process rather than added separately, achieving high thermal performance while managing manufacturing complexity through process integration.
4Area of stationary object
If panel size is increased beyond 5 feet by 5 feet, then coverage area improves, but traditional methods cannot maintain desirable characteristics
Solution Approach 1:
The patent divides large panel manufacturing into multiple smaller sandwich panels that are subsequently assembled together to form the desired large surface area. Each individual sandwich panel maintains manageable dimensions that ensure structural quality and insulation performance, while the segmented panels are configured to collectively provide the required large coverage area.
Data Source
AI summary
Systems and associated methods for manufacturing multiple sandwich panels are provided. In some embodiments, the system can include (1) a control unit; (2) a surface processing module configured to prepare a rolled material by at least one surface treatment process; (3) an environmental management module configured to control and management environmental factors during the surface treatment process and a pressing process; (4) a sealant module configured to apply sealants in sealant patterns on surfaces of flat portions of the rolled material and insulation layers; (5) a pressing module including a top mold, an intermediate mold, a bottom mold and configured to press multiple pairs of the flat portions and insulation layers so to form multiple sandwich panels in the pressing process.