Thermoformable Plastic Panel to Metal Profile Connection

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Solution Overview

Problem

Existing signaling devices with metal or plastic panels face issues such as unsightly deformations, weak connections, and manufacturing complexity due to differential expansion and inadequate fixing methods, making them difficult to handle and assemble.

Innovation Solution

A signaling device with a plastic panel and metal profile that uses thermoformable male assembly means on the panel to fit into female assembly means on the profile, allowing a single-step mechanical assembly and providing a strong, durable connection through temperature-dependent shape adaptation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the profile is fixed to the panel by welding, riveting, or gluing, then the connection is strong, but the panel shows unsightly deformations and the fixing process is complex

Engineering Contradiction:

Improveconnection strengthVSAvoidunsightly deformations

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent changes the physical state of the plastic material by heating it to its melting point, transforming it from a rigid state to a molten state that can flow and adapt to the profile shape, then allows it to solidify, creating a strong bond without visible deformations

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces mechanical fixing methods (welding, riveting, gluing) with a thermal process where the plastic material is melted and poured into the profile, allowing the material itself to form the connection through phase change rather than mechanical fastening

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If the panel is made of metal, then the connection strength is high, but the weight is excessive and handling becomes difficult

Engineering Contradiction:

Improveconnection strengthVSAvoidpanel weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent creates a composite structure where a plastic panel is thermally bonded to a metal profile, combining the light weight and ease of handling of plastic with the structural strength and connection capability of metal, achieving an optimal balance between weight and strength

Inventive Principle:

Principle #40Composite materials

3Stability of the object's composition

If the profile is attached by overmolding, then the assembly is integrated, but the differential expansion causes deformation and the manufacturing process is complex

Engineering Contradiction:

Improveassembly integrationVSAvoidmanufacturing process complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent separates the panel and profile as distinct components that are assembled through a simple thermal bonding process, avoiding the need for integrated overmolding and eliminating the problems of differential expansion and complex manufacturing steps

Inventive Principle:

Principle #1Segmentation

4Weight of moving object

If the panel is made of plastic, then the weight is reduced and handling is easier, but the connection durability is insufficient

Engineering Contradiction:

Improvepanel weightVSAvoidconnection durability

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent enhances the connection durability by changing the temperature parameter, melting the plastic material to its liquid state and pouring it into the profile cavity, where it solidifies to form a strong, durable bond that overcomes the inherent weakness of plastic connections

Inventive Principle:

Principle #35Parameter changes

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 enables a signaling device that is easy to handle, maintains impeccable appearance, and simplifies manufacturing with a strong and durable connection, allowing universal attachment to various supports.

Implementation Method 1

allowing them to pass, once inserted into said female assembly means of the profile, under the effect of a rise in temperature, an initial shape to a final shape complementary to that of said female assembly means of the profile

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP3002746B1Signalling device comprising a panel provided with a profile member for attachment to a mounting

Publication Date: 2020.02.19 WORLDPLAS

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AI summary

The present invention relates to a signaling device comprising a panel (2) made of plastic material provided, on its rear face (5), with a metal profile (10) arranged to cooperate with means for fixing said panel (2) to a support, in particular a post or base. It is characterized in that the rear face (5) of the panel (2) and at least one face of the profile (10) have male (8) and female (7) assembly means respectively arranged to allow assembly between said profile (10) and said panel (2), said male assembly means (8) of the panel (2) being designed in a thermoformable material enabling them to pass, once inserted into said female assembly means (7) of the profile (10), under the effect of a temperature rise, from an initial shape to a final shape complementary to that of said female assembly means (7) of the profile (10), and to retain said final shape under the effect of a temperature fall.