Vacuum Suction Frame for Insulated Panel Bonding
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Solution Overview
Problem
Existing methods for manufacturing elements with insulation layers are laborious, time-consuming, and prone to adhesive blockages, which weaken the bond between the insulation and outer-surface panels, and often require grooves that can lead to inefficient adhesive distribution and structural weaknesses.
Innovation Solution
A method involving two outer-surface panels with a frame structure and a suction arrangement that uses spacer components to create non-unified adhesive spaces for excess adhesive, eliminating the need for grooves and allowing for controlled adhesive distribution, thereby accelerating manufacturing and enhancing bond strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If grooves are formed in the outer panel to remove excess adhesive, then adhesive distribution is controlled, but the manufacturing process becomes laborious and time-consuming
Solution Approach 1:
The suction arrangement is installed beforehand in the frame structure before the bonding process begins. This preliminary setup allows excess adhesive to be automatically removed during bonding through vacuum suction, eliminating the need for subsequent groove formation and manual adhesive removal operations, thus accelerating manufacturing while maintaining precision
Solution Approach 2:
The invention extracts the excess adhesive removal function from the mechanical groove formation process and transfers it to a vacuum suction system. The suction arrangement extracts excess adhesive through suction channels during the bonding process itself, separating the adhesive distribution control from the time-consuming groove formation step
2Quantity of substance
If grooves are formed in the insulation layer surface, then excess adhesive is removed, but the contact surface area between insulation and panel is reduced, weakening the bond
Solution Approach 1:
The suction arrangement acts as an intermediary system between the adhesive application process and the final bonded structure. Instead of modifying the insulation surface with grooves, the intermediary suction system removes excess adhesive through channels in the frame structure, preserving the full contact surface area while still achieving proper adhesive distribution
Solution Approach 2:
The suction channels in the frame structure replicate the adhesive removal function that would otherwise require physical grooves in the insulation layer. By copying this function in the frame structure rather than the insulation surface, the bond strength is maintained while excess adhesive is still effectively removed
3Reliability
If hollow metal profiles are used for suction arrangement, then vacuum is created inside the element, but the weight and space consumption increase
Solution Approach 1:
The invention replaces heavy hollow metal profiles with a lightweight suction arrangement integrated into the frame structure. The suction channels are formed within the existing frame members using lightweight materials, eliminating the need for separate heavy-duty hollow profiles while maintaining the vacuum creation capability through optimized channel geometry
Solution Approach 2:
The frame structure is designed to serve multiple functions: it provides structural support for the element and simultaneously houses the suction channels for adhesive removal. This multi-functionality eliminates the need for separate hollow metal profiles dedicated solely to suction, reducing overall weight and space consumption
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 accelerates the manufacturing process by up to 20%, ensures reliable adhesive distribution without blockages, and increases the structural stiffness of the element by allowing generous adhesive use without compromising suction functionality, resulting in a more even and robust final product.
Implementation Method 1
creating a vacuum with the aid of the suction arrangement inside the frame structure
Implementation Method 2
suck excess adhesive of the adhesive surface and the second adhesive surface into the non-unified adhesive space
Data Source
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AI summary
The invention relates to a method for manufacturing an element, in which method - forming two outer-surface panels (12), to be set opposite to each other, - spreading a first adhesive surface (16.1) on the first outer-surface panel (12.1), - forming a frame structure (20) on top of the first adhesive surface (16.1), to support the outer-surface panels (12) at a distance from each other, - forming a suction arrangement (18) inside the frame structure (20), - setting at least partly periodic separate space components (26) against the inner surface (24) of the frame structure (20) as part of the suction arrangement (18), to form an adhesive space (28), - forming at least one insulation layer (14) inside the frame structure (20), - spreading a second adhesive surface (16.2) between the second outer-surface panel (12.2) and the insulation layer (14), and - creating a vacuum in the frame structure (20) by the suction arrangement (18) and sucking air from the suction arrangement (18) through the adhesive space (28) to suck excess adhesive of the adhesive surface (16) the second adhesive surface into the non-unified adhesive space (28). In addition, the invention relates to a corresponding element.