Description:FIELD OF INVENTION
The present invention pertains to the field of panel manufacturing and, more specifically, to collapsible frames for panels.
BACKGROUND OF THE INVENTION
The manufacturing industry continually seeks innovative solutions to enhance production efficiency, reduce costs, and improve product versatility. In the context of panel manufacturing, the traditional approach often involves the use of multiple dies to create frames of different sizes, leading to significant expenses and limited adaptability to varying layouts or design requirements. Consequently, researchers and engineers have been driven to explore new methodologies that can address these challenges and revolutionize the way panels are produced.
One of the key motivations behind these explorations is to streamline the production process without compromising on the structural integrity and durability of the final product. Manufacturers have long sought ways to optimize resources, minimize wastage, and respond rapidly to changing market demands. By eliminating the need for individual dies for each frame size, manufacturers could significantly reduce production costs and increase their ability to tailor panels to specific customer needs.
Additionally, the quest for a more flexible and adaptable panel manufacturing process has driven research into various materials and techniques that can offer the desired characteristics without compromising on quality. Advanced composite materials prepared by the Glass filled and talc-filled with PP/ABS/Nylon/HDPE have garnered interest due to their favorable properties, such as strength, durability, and versatility, making them potential candidates for improving the manufacturing process.
Furthermore, the integration of automation technologies, such as robotic arms, has emerged as a crucial aspect of modern manufacturing practices. The ability to automate assembly processes not only ensures precision and consistency but also accelerates production rates, enabling manufacturers to meet market demands more efficiently.

In recent times, the manufacturing industry has witnessed advancements in sheet metal bending techniques, allowing for greater customization and adaptability of products. The ability to bend and shape sheet metal accurately has opened up new possibilities for designing panels with different edge profiles and forms, further enhancing the versatility of the manufactured products.
The reliance on multiple dies for different frame sizes not only increases manufacturing expenses but also hinders the ability to customize panels according to specific layout requirements. This lack of adaptability poses a considerable constraint for manufacturers seeking to cater to diverse customer demands and unique design specifications.
Moreover, the inherent inflexibility of conventional panel manufacturing often results in excess production costs due to the need for a separate set of dies for each frame size. This cost inefficiency can be a significant barrier to smaller manufacturers or those facing frequent changes in market demands. A more versatile manufacturing process that eliminates the dependency on numerous dies would not only lead to substantial cost savings but also provide manufacturers with the agility to respond quickly to market fluctuations and customer preferences.
Prior attempts have explored alternative materials and manufacturing techniques. However, existing solutions have not fully overcome the limitations of cost and adaptability inherent in conventional panel manufacturing processes.
The present invention addresses the challenges posed by the existing state of the art and describes a collapsible frame for panels.
OBJECT OF THE INVENTION
The primary object of the present invention is to provide collapsible frames that can be easily adjusted to accommodate various panel dimensions and layouts;
Further object of the present invention is to develop a manufacturing process that reduces production costs by minimizing the number of dies needed for different frame sizes;
Further object of the present invention is to improve the structural integrity and durability of collapsible panels to ensure their reliability and longevity in practical applications.
Another object of the present invention is to integrate robotic automation and sheet metal bending techniques to streamline the assembly process, ensuring precise alignment and integration of components.
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 collapsible frames for panels.
In accordance with an aspect of the present invention, the present invention represents a groundbreaking advancement in the panel manufacturing industry. The invention utilizes a composite compound material comprising glass filled, talc filled with PP/ABS/Nylon/HDPE composite, offering an optimal blend of strength, durability, and versatility.
The manufacturing process of the collapsible frame for panels involves injection moulding to produce corner units, horizontal members, vertical members, frame lock-in units, and dowels. This innovative approach streamlines production, reduces costs, and enhances manufacturing efficiency.
The collapsible frame design allows panels to be adjusted to desired dimensions, providing adaptability to different layouts and customer preferences. Frame lock-in units and dowels ensure secure locking support, blocking movement in three dimensions for stable and secure panels.
According to further aspect of the present invention, the robotic assembly with predefined shapes facilitates the accurate combination and connection of frame components, ensuring precise alignment and integration. The incorporation of automation technologies enhances production efficiency and consistency.
According to another aspect of the present invention, the sheet metal bending techniques further reinforce and customize the collapsible panels. Users employ specialized equipment to bend sheet metal, creating various edge profiles and forms to meet specific panel sizes and layout requirements.
The present invention’s seamless integration into cabinet systems offers a comprehensive and flexible solution for different configurations.
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 complete unit of the collapsible frame for panels in accordance with the embodiments of the present invention;
Fig. 2 illustrates assembled frame 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 collapsible frames for panels offering a novel approach to panel manufacturing that enhances versatility, cost-effectiveness, and adaptability. The invention also describes a comprehensive manufacturing process that utilizes innovative materials, advanced production techniques, and automation technologies to create collapsible panels suitable for various applications.
According to an embodiment of the present invention, the collapsible frames for panels are manufactured using a composite compound material. The composite material consists of a combination of PP (polypropylene), ABS (acrylonitrile butadiene styrene), Nylon, HDPE (High-Density Polyethylene), and glass composite.
The composite compound material used in the invention is a specially formulated blend of multiple components, each chosen for its unique properties and contributions to the overall characteristics of the material. The combination of these elements results in a composite material that offers an ideal balance of strength, durability, versatility, and other desirable attributes, making it well-suited for the manufacturing of collapsible frames for panels.
PP (Polypropylene): Polypropylene is a thermoplastic polymer known for its high tensile strength, chemical resistance, and ability to withstand extreme temperatures. It is lightweight and exhibits excellent impact resistance, making it suitable for various industrial and consumer applications.
ABS (Acrylonitrile Butadiene Styrene): ABS is a thermoplastic known for its excellent impact resistance, strength, and toughness. It also offers good heat resistance and is widely used in applications requiring a combination of rigidity and flexibility.
Nylon: Nylon is a synthetic polymer known for its high strength, durability, and abrasion resistance. It is often used in engineering applications due to its exceptional mechanical properties, such as low friction and high wear resistance.
HDPE (High-Density Polyethylene): HDPE is a type of polyethylene known for its high density, strength, and resistance to chemicals. It is commonly used in applications where moisture resistance and durability are essential, such as in outdoor settings or water-related products.
Glass filler: The addition of glass filler to the composite material enhances its strength, stiffness, and dimensional stability. Glass fillers provide reinforcement to the composite, making it more resistant to deformation and improving its overall structural integrity.
Talc filler: It is a soft and naturally occurring mineral and commonly used as an additive in composite materials. It enhances stiffness, dimensional stability, and heat resistance, making the final product more rigid, less prone to deformation, and capable of withstanding higher temperatures. Talc also improves impact resistance and is cost-effective compared to other fillers or reinforcing agents.
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
According to an embodiment of the present invention, an injection molding process is utilized to produce the collapsible frame components. The composite compound material is fed into the injection molding machine, which shapes it into the desired components. The components include corner units, horizontal units, vertical unit, frame lock units, and dowels. The advantage of this embodiment is that a single set of molds can be employed to produce multiple frame components, eliminating the need for individual dies for each frame size. This results in significant cost savings and manufacturing efficiency.
The collapsible frame allows the panels to be adjusted according to desired dimensions. The collapsible frame consists of corner units, horizontal members, vertical members, frame lock units, and dowels, all designed to facilitate easy expansion and contraction. The corner units are manufactured with uniform dimensions, ensuring uniformity in the overall structure.
The corner units are manufactured with uniform dimensions, ensuring uniformity in the overall structure which ensures consistent stability and anchoring points for the entire collapsible frame, contributing to the overall structural integrity of the panels.
The frame lock units and dowels are designed in two different dimensions, corresponding to the horizontal and vertical units. This design allows for flexibility in adjusting the collapsible frames to different panel dimensions, accommodating various layout requirements or specific customer preferences.
The dowels are intricately designed to fit into the frame’s structure, providing a strong locking support. The combination of frame lock-in members and dowels ensures that movement is effectively blocked in three dimensions when the collapsible frame is assembled, resulting in a stable and secure panel structure.
According to further embodiment of the present invention, the manufacturing process incorporates robotic assembly. Robotic arms equipped with predefined shapes are employed to automate the assembly process. The robotic arms precisely combine and connect the corner units, horizontal members, vertical members, frame lock units, and dowels. This automation ensures accurate alignment and integration of the components, resulting in structurally sound and consistent collapsible panels.
To cover and reinforce the collapsible panels, sheet metal bending technique is used. Specialized equipment is employed to bend the sheet metal, creating the desired edge profiles and shapes. The space between the sheet metal layers is filled with a filler material that acts as both an adhesive, holding the sheets together, and a structural component, reinforcing the overall integrity of the panels. This reinforcement enhances the panels’ rigidity and strength, making them more durable and suitable for various applications.
According to further embodiment, the present invention has the ability to produce collapsible panels in various sizes. By adjusting the dimensions of the horizontal and vertical members, numerous combinations can be created to accommodate different layouts or specific requirements. This feature allows manufacturers to produce panels tailored to specific customer needs without the need for extensive retooling or additional manufacturing processes.
According to further embodiment of the present invention, the collapsible panels can be used to assemble cabinet systems, offering a comprehensive and flexible solution for various cabinet layouts and configurations. The ability to adjust the dimensions of the panels ensures seamless integration within different cabinet designs.
These embodiments are provided to demonstrate the various aspects and features of the apparatus for mixing ingredients and its method of operation. 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:We Claim:
1. A collapsible frame for panels, the said frame comprising:
- a composite material consisting of a base polymer; glass filler; talc filler; and
- components formed from the composite material, including corner units serving as anchor points for the collapsible frame; horizontal units; vertical unit of varying sizes; frame lock units, designed to provide secure locking support and prevent movement in three dimensions when the collapsible frame is assembled, and dowels, designed to interlock with the frame lock units;
characterized by easy expansion, contraction, and adjustability of the collapsible frame to desired dimensions, and facilitating stable and secure panel structures.
2. The collapsible frame 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.
3. The collapsible frame as claimed in claim 1, wherein the injection molding process is utilized to manufacture the corner units, horizontal members, vertical members, frame lock units, and dowels, allowing for multiple frame components to be produced using a single set of molds.
4. The collapsible frame as claimed in claim 1, further comprises robotic assembly with predefined shapes for accurate combination and connection of the corner units, horizontal members, vertical members, frame lock units, and dowels, ensuring precise alignment and integration of the components.
5. The collapsible frame as claimed in claim 1, wherein sheet metal bending is used to cover and reinforce the collapsible frame, creating desired edge profiles and shapes, with a filler material between the sheet metal layers acting as both an adhesive and a structural component, reinforcing the overall integrity of the collapsible frame.
6. A method of manufacturing collapsible frames for panels, the said method comprising the steps of:
- injecting a composite compound material comprising a base polymer; glass filler; talc filler into molds to create corner units, horizontal members, vertical members, frame lock units, and dowels;
- assembling the corner units, horizontal panels, vertical panels, frame lock units, and dowels using robotic arms with predefined shapes to ensure accurate alignment and integration;
- applying filler material to enhance structural integrity;
- adjusting the dimensions of the horizontal and vertical members to create collapsible frames of different sizes to accommodate various panel dimensions and layout requirements.
characterized by use of sheet metal bending equipment to cover and reinforce the collapsible frames, allowing for customization and adaptability of the panels and integration of robotic arms with predefined shapes into the assembly process, ensuring streamlined and efficient production of the collapsible frames.
7. The method as claimed in claim 6, wherein the injection molding process enables multiple frame components to be produced using a single set of molds, reducing the need for individual dies.
8. The method as claimed in claim 8, further comprising integrating the collapsible frames into cabinet systems.