Wall Board Edge Strip Integration for Cost-Efficient Production
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Solution Overview
Problem
Existing methods for mounting panelling on walls, such as wooden panels and plasterboards, face challenges in achieving an aesthetically pleasing appearance with uncomplicated and cost-efficient manufacturing, while requiring significant investment in production lines and high manufacturing volumes for profitability.
Innovation Solution
A method involving mechanical surface processing of edge sides of a body element to create flat surfaces for edge strips, followed by application and profiling of these strips to integrate them into the wall board, allowing for cost-efficient production with integrated edge strips that provide robust and aesthetically appealing joints without the need for extensive production line investments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If edge strips are molded into the wall board during production, then the joint appearance is aesthetically appealing and the design is robust, but the production line requires relatively large investment and high manufacturing volume is needed for profitability
Solution Approach 1:
The edge strip is separated from the wall board body and attached as a distinct component. The method involves mechanically processing the edge side of the wall board, applying adhesive, and then attaching the edge strip separately, rather than molding it as an integrated part. This segmentation allows for simpler production equipment while achieving the same aesthetic joint appearance.
Solution Approach 2:
The edge side of the wall board is mechanically processed in advance to create a flat surface structure before the edge strip is attached. This preliminary surface preparation ensures proper adhesion and aesthetic appearance without requiring complex molding equipment during the main production process.
2Device complexity
If edge strips are attached after body element production, then production line investment is reduced, but the surface flatness and integration quality may be compromised
Solution Approach 1:
The edge side of the body element is mechanically processed in advance to remove the surrounding layer and create a flat surface structure. This preliminary action ensures that when the edge strip is later attached, it aligns perfectly with the main side, achieving the desired surface flatness and integration quality.
Solution Approach 2:
An adhesive layer is applied as an intermediary between the processed edge side and the edge strip. This adhesive mediator ensures strong bonding and maintains the flat, unbroken surface appearance, compensating for the fact that the edge strip is attached separately rather than being molded integrally.
3Manufacturing precision
If mechanical surface processing is applied to edge sides, then flat surface structure is achieved for better edge strip integration, but additional processing steps are required
Solution Approach 1:
The mechanical surface processing of the edge side is performed as a preliminary action before edge strip attachment. This processing removes the surrounding layer and creates a flat surface structure that facilitates proper edge strip integration, ensuring aesthetic appearance and structural integrity.
Solution Approach 2:
The mechanical surface processing is applied specifically to the edge side of the body element, not the entire board. This localized processing achieves the necessary flat surface for edge strip integration while minimizing additional processing steps and maintaining efficiency in the overall manufacturing process.
Data Source
Figure 1a~1e
Figure 2
Figure 3
AI summary
A wall board (100) is produced based on a body element (110), which essentially has the shape of a rectangular parallelepiped including two opposing main sides (110A, 110B) and four edge sides (111, 112, 113, 114) according to the following method: mechanical surface processing of a first edge side (111), wherein the first edge side (111) attains a flat surface structure, which extends from a first (110A) to a second (110B) of the main sides; applying a first surface treatment layer (160) on the first edge side (111); and arranging a first edge strip (120) along the first edge side (111). The first edge strip (120) contains: a first distal edge surface (220D), a thereto opposing first proximal edge surface (220P) which is flat, and a first primary surface (220A) between the first proximal edge surface (220P) and the first distal edge surface (220D), The first edge strip (120) being arranged with the first proximal edge surface (220P) against the first edge side (111) such that the first primary surface (220A) and the first main side (110A) of the body element (110) form a first, flat and essentially unbroken surface. A first reinforcement layer (140) is also applied on the first, flat and essentially unbroken surface, which first reinforcement layer (140) covers the first main side (110A) and the first primary surface (220A).