Description:DESCRIPTION OF INVENTION
FIELD OF INVENTION
The present invention pertains to the field of manufacturing systems and processes;
More particularly, the present invention related to the domain of panel and cabinet production encompassing methods and apparatus for fabricating panels and cabinets with adjustable dimensions and versatile configurations.
BACKGROUND OF THE INVENTION
The manufacturing of panels and cabinets has long been a fundamental process in various industries, catering to a wide range of applications. Traditional methods of producing panels typically involve the use of fixed dies and molds to create panels of specific dimensions. While these methods have been widely adopted, they come with several inherent limitations that have posed challenges for manufacturers:
Traditional panel production processes are rigid and lack adaptability. Manufacturers often require multiple sets of dies to produce panels of varying sizes and configurations. This lack of flexibility results in increased production costs, inventory management challenges, and longer lead times for customization.
The creation of customized panels or cabinets necessitates the production of specialized dies or molds. Developing and maintaining these dies can be an expensive and time-consuming process, especially for manufacturers dealing with a diverse product line.
The storage and management of numerous dies for different panel sizes can be space-intensive and logistically challenging for manufacturing facilities. This constraint can limit a manufacturer’s ability to respond quickly to changing market demands.
In an ever-evolving market, the ability to adapt quickly to new design trends or customer requirements is essential. Conventional panel production methods often lack the agility needed to address these dynamic demands effectively.
Fixed dies are designed for specific panel sizes, resulting in material wastage when producing smaller or larger panels. This not only increases material costs but also contributes to environmental concerns associated with excess waste.
Manufacturers are required to make a significant upfront investment in dies and molds before production can even begin. This cost can be prohibitive for small-scale manufacturers or startups looking to enter the market.
In light of these limitations, there exists a significant need for an innovative approach to panel manufacturing that addresses these challenges.
The present invention addresses the challenges posed by the existing state of the art and describes an adaptive panel production system with collapsible frames and modular components.
OBJECT OF THE INVENTION
The primary object of the present invention is to provide an adaptive panel production system with collapsible frames and modular components to significantly reduce manufacturing costs associated with traditional panel production by eliminating the need for multiple dies and molds for different panel dimensions;
Further object of the present invention is to provide manufacturers with a highly flexible and adaptable panel production system for rapid adjustments in panel dimensions and configurations, enabling manufacturers to respond swiftly to changing market demands and design requirements.
SUMMARY OF THE INVENTION
Embodiments of the present disclosure present technological improvements as solution to one or more of the above-mentioned technical problems recognized by the inventor in conventional practices and existing state of the art.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter. Further, while certain disadvantages of prior technologies may be noted or discussed herein, the claimed subject matter is not intended to be limited to implementations that may solve or address any or all of the disadvantages of those prior technologies.
The present invention discloses an adaptive panel production system with collapsible frames and modular components.
.
The objects and the advantages of the invention are achieved by the process elaborated in the present disclosure.
BRIEF DESCRIPTION OF DRAWINGS:
The accompanying drawings constitute a part of this specification and illustrate one or more embodiments of the invention. Preferred embodiments of the invention are described in the following with reference to the drawings, which are for the purpose of illustrating the present preferred embodiments of the invention and not for the purpose of limiting the same.
For simplicity and clarity of illustration, the drawing figures illustrate the general manner of construction, and descriptions and details of well-known features and techniques may be omitted to avoid unnecessarily obscuring the invention. Additionally, elements in the drawing figures are not necessarily drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve understanding of embodiments of the present invention. The same reference numerals in different figures denotes the same elements.
In the drawings:
Fig. 1 illustrates basic frame or type 1 assembly for panels in accordance with the embodiments of the present invention;
Fig. 2 illustrates short frame or type 2 assembly in accordance with the embodiments of the present invention;
Fig. 3 shows type 3 assembly in accordance with the embodiments of the present invention
Fig. 4 describes type 4 assembly in accordance with the embodiments of the present invention
Fig. 5 illustrates type 5 assembly in accordance with the embodiments of the present invention
Fig. 6 shows type 6 assembly in accordance with the embodiments of the present invention
DETAILED DESCRIPTION OF THE INVENTION
The following detailed description illustrates embodiments of the present disclosure and ways in which the disclosed embodiments can be implemented. Although some modes of carrying out the present disclosure have been disclosed, those skilled in the art would recognize that other embodiments for carrying out or practising the present disclosure are also possible.
The present invention describes an adaptive panel production system with collapsible frames and modular components. It introduces a solution for panel manufacturing, specifically focusing on creating a versatile cabinet system with collapsible panels of different dimensions while eliminating the need for traditional fixed dies, enabling significant cost savings and enhanced manufacturing flexibility.
A collapsible frame assembly forms the core of the invention and comprises a limited number of components designed for expandability and contractibility. These components form the foundation of the cabinet system, allowing easy modification of dimensions to meet various layout and design requirements.
According to an embodiment of the present invention, the main frame structure consists of adjustable sections that can be extended or collapsed, providing the fundamental mechanism for achieving different cabinet dimensions. These sections play a pivotal role in customizing the cabinet’s width, height, and depth.
To ensure stability and structural integrity, the frame assembly incorporates specialized connecting joints (1). These joints are meticulously designed to securely link the various sections together, preventing unintended movements or deformations during the cabinet’s usage. They are engineered to lock in place when the frame is extended or collapsed.
The collapsible frames are constructed using lightweight yet durable composite materials. Injection molding is employed to manufacture the key components, including corner units, horizontal members, vertical members, and frame lock units. These components are composed of a composite compound material consisting of polypropylene (PP), acrylonitrile butadiene styrene (ABS), nylon, high-density polyethylene (HDPE), and glass composite.
The present invention eliminates the need for multiple dies traditionally required in panel production. Instead, a single set of molds is utilized to produce multiple frame components. This approach significantly enhances manufacturing flexibility and adaptability, as it removes the requirement for separate dies for each frame size.
The material composition of the product is crucial to its performance. It primarily comprises glass fiber-reinforced, talc-filled polypropylene. This composite material includes:
Base Polymer: Predominantly polypropylene, accounting for 62.5% to 82.5% of the material.
Reinforcement: Glass fibers, added to enhance strength and rigidity. The content typically ranges from 15% to 25%.
Filler: Talc is introduced to improve stiffness and dimensional stability, making up approximately 2.5% to 5% of the material by weight.
The assembly process involved in achieving various cabinet dimensions includes the following steps:
Creation of the main frame by joining corner units and horizontal/vertical units.
Assembling the frame without horizontal arms, resulting in the smallest frame.
Adjusting dimensions by manipulating horizontal and vertical units within the frame.
Creating combinations of different frames to obtain a wide range of cabinet sizes as illustrated in Fig. 3- 6.
According to an embodiment of the present invention, this assembly process is guided by a mathematical module that provides precise instructions and calculations for achieving the desired cabinet dimensions.
Integral to the invention is a mathematical module that aids in the assembly process. This module offers guidance for creating combinations and achieving a diverse range of cabinet dimensions. It includes algorithms, calculations, and guidelines to ensure precision and consistency in manufacturing. The said mathematical module employs geometric formulas, material tolerances, and iterative processes to calculate and fine-tune panel dimensions
The invention allows for variations in cabinet dimensions based on input parameters provided, including dimensions for corner units (A), horizontal unit (D), vertical units (B and C), and joining mechanism (E). These parameters, combined with the assembly process and mathematical module, facilitate the creation of cabinets with diverse dimensions to meet various design and space requirements.
The present invention aids panel manufacturing by introducing a collapsible frame system for versatile cabinet construction. It eliminates the need for multiple dies, enhances manufacturing flexibility, and employs composite materials to create durable yet lightweight components. The invention’s adaptability, guided by a mathematical module, allows for the production of cabinets in a wide range of dimensions, making it a groundbreaking solution in the field of cabinet manufacturing.
These embodiments are provided to demonstrate the various aspects and features of the adaptive panel production system with collapsible frames and modular components. The invention is not limited to these specific embodiments and can be implemented in different configurations and variations without departing from the scope of the invention as defined in the claims.
, Claims:CLAIMS:
We Claim:
1. An adaptive panel production system with collapsible frames and modular components, the said system comprising:
- a collapsible frame assembly with modular components designed for expandability and contractibility, enabling modification of panel dimensions;
- a specialized connecting joint ensuring secure linkage of frame components;
- lightweight and durable composite materials comprising polypropylene (PP), acrylonitrile butadiene styrene (ABS), nylon, high-density polyethylene (HDPE), and glass composite;
- a mathematical module incorporating algorithms, calculations, and guidelines, facilitating precise panel assembly and customization of dimensions
characterized by the collapsible frame assembly allowing for adjustment of panel width, height, and depth, accommodating various design and layout requirements and by a human-machine interface (HMI) integrated with the mathematical module, enabling operators to input specific panel dimensions and desired parameters, with the mathematical module generating assembly instructions based on these inputs.
2. The adaptive panel production system as claimed in Claim 1, wherein the connecting joints securely lock frame components in place during panel usage, preventing unintended movements and deformations.
3. The adaptive panel production system as claimed in Claim 1, wherein the composite material has a base polymer selected from the group of PP (polypropylene), ABS (acrylonitrile butadiene styrene), Nylon, HDPE (High-Density Polyethylene), constituting 62.5% to 82.5% of the composite material; glass filler, providing added strength and rigidity to the composite material, constituting 15% to 25% of the composite material; and talc filler, enhancing stiffness and dimensional stability, constituting 2.5% to 5% by weight of the composite material.
4. The adaptive panel production system as claimed in Claim 1, wherein injection molding is utilized for manufacturing key components of the collapsible frame assembly, including corner units, horizontal members, vertical members, and frame lock units.
5. The adaptive panel production system as claimed in Claim 1, wherein the mathematical module employs geometric formulas, material tolerances, and iterative processes to calculate and fine-tune panel dimensions.