Thermally Welded Cutting Board Composite for Hygienic Edges
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Solution Overview
Problem
Existing cutting boards for food, whether made of wood or plastic, fail to meet hygiene standards due to microbial colonization, and existing composite materials with removable plastic sheets have hygienic and manufacturing issues, such as exposed edges and complex production processes.
Innovation Solution
A composite material made of multiple thermally welded plastic plates with a seamless weld seam at all edges, where the plates have varying thicknesses to ensure rigidity and easy replacement, using polyethylenes and their copolymers, and produced using laser thermal welding for efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If plastic plates are connected at peripheral corners only, then the structure is simple to manufacture, but the exposed edges create hygienic problems with dirt accumulation and microbial colonization
Solution Approach 1:
The patent merges the connection function with the edge sealing function by thermally welding all edges of adjacent plastic plates together. This creates an integrated seamless structure that eliminates the hygienic problems of exposed edges while maintaining manufacturing simplicity through a single welding process.
Solution Approach 2:
The thermal welding process creates a seamless bond between plastic plates that acts as a continuous protective barrier, similar to how flexible films create sealed environments. This seamless connection prevents dirt and microorganisms from penetrating into edge gaps.
2Object-affected harmful factors
If circumferential bonding with thermoplastic rubber is used to seal edges, then hygienic standards are improved, but the bond ages rapidly under dishwasher conditions and detaches
Solution Approach 1:
The patent changes the material parameter from thermoplastic rubber to thermally welded plastic, and changes the connection method from chemical bonding to thermal fusion. This creates a bond that is inherently resistant to dishwasher conditions (temperature and moisture) while maintaining seamless hygienic edges.
Solution Approach 2:
The patent uses composite construction with multiple plastic plates of different thicknesses (first plates with first thickness, second plate with second thickness) connected by thermal welding. This composite structure provides both hygienic seamless edges and durable long-term stability under harsh cleaning conditions.
3Object-affected harmful factors
If laser thermal welding is used to connect plastic plates, then hygienic standards are improved with seamless weld seams, but production complexity and time increase
Solution Approach 1:
The patent replaces mechanical connection methods (screws, clips, adhesives) with laser thermal welding, which uses optical energy to melt and fuse plastic edges. This substitution creates seamless hygienic connections while the laser's precision actually simplifies the process by requiring no additional alignment or bonding steps.
Solution Approach 2:
The laser thermal welding process exploits the phase transition of plastic from solid to molten state and back to solid. The laser heats the plastic edges to melting point, fuses them together, and upon cooling creates a seamless permanent bond that is hygienically flawless.
4Ease of manufacture
If all plastic plates have the same thickness, then manufacturing is simplified, but the board lacks sufficient rigidity when plates are worn and need replacement
Solution Approach 1:
The patent applies different thicknesses to different parts of the composite structure: first plates have a first thickness optimized for cutting surface wear resistance, while the second plate has a greater second thickness optimized for structural rigidity and support. This local differentiation solves both manufacturing and strength requirements.
Solution Approach 2:
The patent creates a composite structure with heterogeneous plate thicknesses where the thicker second plate provides structural support and rigidity, while the thinner first plates provide wear-resistant cutting surfaces. This composite approach optimizes both mechanical properties and manufacturing efficiency.
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 provides a hygienically safe, durable, and cost-effective cutting board that meets HACCP standards, allowing users to easily replace worn-out surfaces without special tools, reducing waste and maintenance costs while ensuring the board remains rigid and easy to clean.
Implementation Method 1
All adjacent panels are thermally welded together at all edges of the composite. The thermal welding smoothes all side edges of the composite material.
Implementation Method 2
produced using laser thermal welding for efficient manufacturing
Data Source
Figure 1~2
AI summary
A composite material (1) has a plurality of first plates (2a-g) arranged one on top of the other. The first plates each consist of the same plastic and each have the same surface area and the same first thickness (d2). All adjacent panels are thermally welded together at all edges (11, 12) of the composite material (1). The composite material (1) can be used as a cutting board for food. The composite material is produced by providing a plurality of first plates (2a-g) which consist of the same plastic, which each have a first thickness (d2) and which each have the same surface area. The first plates (2a-g) are arranged congruently one on top of the other in order to obtain a stack of plates. Then all the plates (2a-g, 3) of the plate stack are thermally welded together to obtain the composite material (1).