Composite Waveform Panel Forming Apparatus
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Solution Overview
Problem
Conventional methods for forming waveform panels are limited in creating composite waveforms, requiring multiple corrugation cores, large installation spaces, high costs, and lengthy manufacturing times, with weak coupling forces between panels leading to potential damage under external stress.
Innovation Solution
A single apparatus with a fixed lower mold and reciprocating upper mold, featuring first and second mold units for forming right and obtuse triangular waveforms, and a third mold unit for linearly pressing the base materials to attach them, allowing rapid panel formation and enhanced coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple corrugation cores are used to form composite waveforms, then the waveform forming capability is improved, but the device complexity and installation space increase
Solution Approach 1:
The patent combines multiple waveform forming functions into a single corrugation core by integrating first, second, and third waveforming sections with different corrugation patterns (right triangular, obtuse triangular, and linear pressing sections) along the longitudinal direction of the core. This merging approach eliminates the need for multiple separate corrugation cores while maintaining the ability to form composite waveforms, thereby reducing device complexity and installation space.
Solution Approach 2:
The patent extends the waveform forming capability along the longitudinal dimension of the single corrugation core rather than using multiple cores in parallel. By arranging different waveforming sections (right triangular, obtuse triangular, linear pressing) sequentially along the length of the core, the system achieves composite waveform formation through spatial extension in one dimension, avoiding the need for multiple cores.
2Adaptability or versatility
If multiple corrugation cores are used to form composite waveforms, then the waveform forming capability is improved, but the manufacturing time increases
Solution Approach 1:
The patent merges multiple waveform forming functions into a single corrugation core that performs all waveforming operations (right triangular, obtuse triangular, and linear pressing) in one continuous pass through the extrusion process. This eliminates the need for multiple separate processing steps or cores, thereby reducing manufacturing time while maintaining composite waveform capability.
3Ease of operation
If panels are coupled using only edge fastening with bolts, then the assembly simplicity is improved, but the coupling force between panels is weak
Solution Approach 1:
The patent applies different fastening characteristics to different regions of the panel structure. The waveformed panels create localized interlocking features at the edges through the right triangular and obtuse triangular corrugations, while the linear pressing section provides enhanced central region bonding. This local differentiation of fastening qualities strengthens the overall coupling without compromising assembly simplicity.
4Productivity
If strong external force is exerted on the entire panel at one time through pressing, then the waveform forming speed is improved, but the panel may tear or be damaged
Solution Approach 1:
The patent segments the waveform forming process into three distinct sections along the corrugation core: right triangular waveform section, obtuse triangular waveform section, and linear pressing section. This segmentation distributes the forming action progressively along the panel length rather than applying force all at once, reducing the risk of panel tearing while maintaining efficient waveform formation.
Solution Approach 2:
The patent implements preliminary waveforming actions through the right triangular and obtuse triangular sections before the final linear pressing section. This preliminary formation of wave patterns prepares the panel structure to better withstand the subsequent pressing force, preventing damage while achieving the desired waveform configuration.
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
Enables rapid formation of panels with improved load distribution and increased load-carrying capacity, reducing manufacturing time and costs while enhancing the coupling strength between panels.
Implementation Method 1
an upper mold which is provided above the lower mold and reciprocates up and down in a vertical direction, and compressing a plurality of base materials fed to front ends of the lower and upper molds
Implementation Method 2
a third mold unit which is provided behind the second mold unit, and linearly presses the base materials compressed by the second mold unit in a direction from front to rear, thereby attaching the base materials to each other
Data Source
AI summary
Disclosed herein is an apparatus and method for forming a panel. The apparatus includes a first mold unit may include a right-angled upper mold provided on the front portion of an upper mold to reciprocate vertically, and a right-angled lower mold provided on the front portion of a lower mold, thus compressing base materials to impart a pattern of a right triangular waveform. A second mold unit may include an obtuse upper mold provided on the central portion of the upper mold to reciprocate in a direction inclined relative to a progressing direction of the base materials, and an obtuse lower mold provided on the central portion of the lower mold, thus compressing the base materials to impart a pattern of an obtuse triangular waveform. A third mold unit may be provided behind the second mold unit and linearly presses the base materials in a direction from front to rear.