Reinforced sandwich panels using expandable foam materials and their manufacturing method

Abstract

This application relates to a reinforced sandwich panel using expandable foam material and a method for manufacturing the same. A reinforced sandwich panel includes: two skin panels; a foam core disposed between the two skin panels; and an expandable frame disposed within the foam core.

Description

Technical Field

[0001] This disclosure generally relates to sandwich panels, and more specifically to reinforced sandwich panels using expandable foam materials and methods for manufacturing the same. Background Technology

[0002] Sandwich panels, also known as composite sandwich panels, typically consist of a low-density core sandwiched between two panels made of different materials. Sandwich panels have a high strength-to-weight ratio, which makes them suitable for a variety of applications, such as aerospace.

[0003] However, there is a need for sandwich panels with reinforced structural support and variable core functionality, as well as sandwich panels that do not require a curing process or can be formed on-site as an autoclave process. Summary of the Invention

[0004] This invention summary is intended only to describe a simplified summary of some aspects of one or more implementations of this disclosure. It is not a broad overview, nor is it intended to identify key or essential elements of the teachings, nor to depict the scope of this disclosure. Rather, its purpose is solely to present one or more concepts in a simplified form as a prelude to the detailed description that follows.

[0005] The foregoing and / or other aspects and benefits illustrated in this disclosure can be achieved by providing a reinforced sandwich panel comprising: two skin panels; a foam core disposed between the two skin panels; and an expandable frame disposed within the foam core.

[0006] The reinforced sandwich panel may also include one or more adhesive layers, wherein the one or more adhesive layers bond at least one of the foam core and the expandable frame to the two skin panels.

[0007] The reinforced sandwich panel may also include a flexible membrane, wherein the foam core may be encapsulated by the flexible membrane, and wherein the flexible membrane may bond the foam core to at least one of the skin panel or the expandable frame.

[0008] The foam core may include one or more expandable material layers and one or more additional layers, wherein the one or more additional layers may include at least one of reinforcing fibers or adhesive layers.

[0009] An expandable frame can be integrated with two skin panels, wherein the expandable frame can separate the skin panels by a predetermined distance.

[0010] An expandable frame can elastically expand from a contracted state to an expanded state, and wherein the expandable frame can be biased toward the expanded state, wherein the expandable frame can include a plurality of interconnected and expandable struts configured to expand from a contracted state to an expanded state, and wherein the plurality of interconnected and expandable struts can be configured to be locked in at least one of the contracted state and the expanded state.

[0011] Expandable frames may include one or more of the following: metal, ceramic, paper or fiber products, thermoplastic materials, thermosetting materials, or combinations thereof.

[0012] An expandable frame can improve the thermal or electrical conductivity of at least one of the foam core or the sandwich panel.

[0013] The foregoing and / or other aspects and benefits illustrated in this disclosure can also be achieved by providing a reinforced multi-core sandwich panel comprising: two or more skin panels; and two or more cores disposed between the two or more skin panels; wherein at least one of the two or more cores may comprise a foam core having an expandable frame disposed therein.

[0014] The reinforced multi-core sandwich panel may also include one or more diaphragms disposed between two or more cores.

[0015] The reinforced multi-core sandwich panel may also include one or more adhesive layers disposed between two or more cores and two or more skin panels or one or more diaphragms, wherein the one or more adhesive layers can bond at least one of the two or more cores to the two or more skin panels or one or more diaphragms.

[0016] At least one of the two or more cores may have functional characteristics different from the other two or more cores.

[0017] The foregoing and / or other aspects and benefits illustrated in this disclosure can also be achieved by providing a method for manufacturing a reinforced sandwich panel frame, the method comprising: placing a first skin panel; placing an expandable frame on the first skin panel; placing a second skin panel on the expandable frame; and attaching the expandable frame to the first skin panel and the second skin panel, wherein the expandable frame may have a first height separating the first skin panel and the second skin panel when the expandable frame is in a contracted state, and a second height separating the first skin panel and the second skin panel when the expandable frame is in an expanded state, and wherein the second height is greater than the first height.

[0018] The foregoing and / or other aspects and benefits illustrated in this disclosure can also be achieved by providing a method for manufacturing a reinforced sandwich panel, the method comprising: placing a reinforced sandwich panel frame; inflating the reinforced sandwich panel frame; placing a foam core within the reinforced sandwich panel frame; and inflating the foam core, wherein the reinforced sandwich panel frame may include two skin panels and an inflatable frame disposed between the two skin panels, and wherein the inflatable frame may have a first height separating the skin panels when the inflatable frame is in a contracted state, and a second height separating the skin panels when the inflatable frame is in an inflated state, and wherein the second height is greater than the first height.

[0019] The method may further include at least one of the following steps: reinforcing the reinforced sandwich panel; trimming the reinforced sandwich panel; sealing the reinforced sandwich panel; and removing the reinforced sandwich panel, wherein placing the reinforced sandwich panel frame may include placing the reinforced sandwich panel frame at the location where the reinforced sandwich panel will be installed.

[0020] Inflating a reinforced mezzanine panel frame can include using an inflatable frame to allow the reinforced mezzanine panel frame to elastically expand to an inflated state.

[0021] The expandable frame can be locked in the expanded state to maintain a predetermined distance between the skin panels of the reinforced mezzanine panel frame.

[0022] Inflating a reinforced sandwich panel frame can include inflating a foam core to inflate the reinforced sandwich panel frame to an inflated state, wherein the expandable material of the foam core can expand at room temperature, and wherein the expandable frame generates a static field capable of attracting the expandable material of the foam core.

[0023] Reinforcing and strengthening sandwich panels may include placing vacuum bags around the reinforced sandwich panel and applying vacuum to the reinforced sandwich panel.

[0024] The reinforced sandwich panel may include applying either curing pressure or temperature to the reinforced sandwich panel and fusing at least one of the frame or foam core to the skin panel.

[0025] Further areas of application will become apparent from the detailed description provided below. It should be understood that while the detailed description and specific examples illustrate preferred embodiments of this disclosure, they are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0026] The accompanying drawings, which are incorporated in and form part of this specification, illustrate implementations of the teachings and, together with the description, serve to explain the principles of this disclosure. In the drawings:

[0027] Figure 1An enhanced mezzanine panel according to an implementation of this disclosure is shown.

[0028] Figure 2 An enhanced multi-core sandwich panel according to an implementation of the present disclosure is shown.

[0029] Figure 3 A method for manufacturing a reinforced sandwich panel frame according to an implementation of the present disclosure is shown.

[0030] Figure 4 An enhanced mezzanine panel frame is shown, depending on the implementation method.

[0031] Figure 5 An enhanced mezzanine panel frame is shown, depending on the implementation method.

[0032] Figure 6 A method for manufacturing a reinforced sandwich panel according to an implementation of the present disclosure is shown.

[0033] Figure 7 The implementation of a method for manufacturing reinforced sandwich panels is shown.

[0034] Figure 8 The implementation of a method for manufacturing reinforced sandwich panels is shown.

[0035] Figures 9 to 10 The implementation of a method for manufacturing reinforced sandwich panels is shown.

[0036] Figure 11 A flowchart illustrating the aircraft manufacturing and maintenance methods is shown.

[0037] Figure 12 A block diagram of the aircraft is shown.

[0038] It should be noted that some details in the accompanying drawings have been simplified and drawn to facilitate understanding of this teaching rather than to maintain strict structural accuracy, detail, and proportion. Detailed Implementation

[0039] Reference will now be made in detail to exemplary implementations of this teaching, examples of which are shown in the accompanying drawings. Typically, the same reference numerals are used in all the drawings to denote the same or similar parts.

[0040] Throughout the specification and claims, unless the context clearly specifies otherwise, the following terms shall have the meaning explicitly associated with this document. Phrases as used herein, such as “in an implementation,” “in some implementations,” and “in some implementations,” do not necessarily refer to the same implementation(s), although they may. Furthermore, phrases as used herein, such as “in another implementation” and “in some other implementations,” do not necessarily refer to different implementations, although they may. As described below, various implementations can be readily combined without departing from the scope or spirit of this disclosure.

[0041] As used herein, the term “or” is an inclusion operator and is equivalent to the term “and / or” unless the context clearly indicates otherwise. The term “based on” is not exclusive and allows for basing on additional factors not described unless the context clearly indicates otherwise. In the specification, the statement “at least one of A, B, and C” includes implementations that include A, B, or C, multiple examples of A, B, or C, or combinations of A / B, A / C, B / C, A / B / B / B / B / C, A / B / C, etc. Furthermore, throughout the specification, the meanings of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on”. Similarly, implementations of this disclosure may suitably include elements A, B, C, etc., consist of elements A, B, C, etc., or consist substantially of elements A, B, C, etc.

[0042] It will also be understood that although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, without departing from the scope of this disclosure, a first object, component, or step may be referred to as a second object, component, or step, and similarly, a second object, component, or step may be referred to as a first object, component, or step. Both the first object, component, or step and the second object, component, or step are objects, components, or steps, but they are not considered to be the same object, component, or step. It will also be understood that the terms “includes,” “including,” “comprises,” and / or “comprising,” when used in this specification, specify the presence of the stated feature, step, operation, element, and / or component, but do not exclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Furthermore, as used herein, the term “if” may be interpreted as “when,” “after,” “in response to determination,” or “in response to detection,” depending on the context.

[0043] Unless otherwise specified, all physical properties defined below are measured at 20°C to 25°C.

[0044] When any numerical range is referred to herein, such a range is understood to include every and all numbers and / or fractions between the minimum and maximum values ​​of the range, as well as the endpoints. For example, a range of 0.5% to 6% would explicitly include all intermediate values ​​such as 0.6%, 0.7%, and 0.9%, all of which go up to and include 5.95%, 5.97%, and 5.99%, as well as many other values. Unless the context clearly indicates otherwise, the same applies to every other numerical property and / or element range set forth herein.

[0045] Furthermore, all numerical values ​​are expressed as “about” or “approximately” and take into account experimental errors and variations expected by those skilled in the art. It should be understood that all numerical values ​​and ranges disclosed herein are approximate values ​​and ranges. The terms “about” or “basically” and “substantially” or “approximately” with respect to quantities or measurements mean that the stated characteristic, parameter, or value does not need to be precisely achieved. Conversely, deviations or variations, including, for example, tolerances, measurement errors, measurement accuracy limitations, and other factors known to those skilled in the art, may occur in quantities that do not preclude the effects that the characteristic is intended to provide. As used herein, “about” means within + / -10% of the target value, maximum value, or minimum value.

[0046] Unless otherwise stated, all percentages and quantities expressed herein and elsewhere should be understood as weight percentages. The percentages and quantities given are based on the active weight of the material. For example, for active ingredients provided as solutions, the quantities given are based on the amount of active ingredient without the amount of solvent, or can be determined by the weight loss after solvent evaporation.

[0047] Regarding the processes, methods, techniques, and workflows disclosed herein, some operations can be combined and / or the order of some operations can be changed, depending on the implementation methods, techniques, and workflows.

[0048] Figure 1 An enhanced mezzanine panel according to an implementation of this disclosure is shown. (As...) Figure 1 As shown, the reinforced sandwich panel 10 includes two skin panels 200, a foam core 300 disposed between the two skin panels 200, and an expandable frame 400 disposed within the foam core 300. The reinforced sandwich panel 10 may include one or more adhesive layers 500. The one or more adhesive layers 500 may bond at least one of the foam core 300 and the expandable frame 400 to the two skin panels 200.

[0049] like Figure 1As shown, the reinforced sandwich panel 10 may have a width 20 along the y-axis, a length 30 along the x-axis, and a height 40 along the z-axis. The reinforced sandwich panel 10 may have an average height 40 ranging from about 0.05 inches to about 5 inches. For example, the reinforced sandwich panel 10 may have an average height 40 ranging from about 0.50 inches to about 4 inches, from about 0.50 inches to about 3 inches, or from about 0.50 inches to about 2 inches.

[0050] The skin panel 200 may be formed of a material with high tensile and compressive strength, such as metals (e.g., titanium, aluminum, steel, etc.), composite materials (e.g., carbon fiber reinforced polymer (CFRP), carbon fiber reinforced plastic (CRP), carbon fiber reinforced thermoplastic (CFRTP), etc.), glass fiber, ceramics, etc. For example, the skin panel 200 may include one or more of metals, ceramics, thermoplastic materials, thermosetting materials, or combinations thereof. The skin panel 200 may include one or more of thermoplastic or thermosetting materials. For example, the skin panel 200 may include one or more of phenolic resin, epoxy resin, polypropylene (PP), polyamide (PA), polyethylene terephthalate (PET), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polycarbonate (PC), polyetherimide (PEI), polyphenylene sulfone (PPSU), thermoplastic polyurethane (TPU), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethane (PU), or combinations thereof. In some implementations, at least one of the skin panels 200 includes a metal, such as aluminum.

[0051] At least one of the skin panels 200 can be an uncured composite skin panel or a prepreg. Carbon fiber sheets impregnated with uncured thermosetting or thermoplastic resins are generally referred to as “prepreg.” As used herein, the term “prepreg” refers to a pre-impregnated composite sheet, such as epoxy-impregnated unidirectional composite tape or carbon fiber. Prepregs can be flexible until cured, typically by heat and pressure curing or in an autoclave. Other types of carbon fibers include “dry fibers” unimpregnated with thermosetting resins, but may include tackifiers or adhesives. Dry fibers can be impregnated with resin prior to curing. For thermosetting resins, curing is a unidirectional process known as curing, while for thermoplastic resins, the resin can reach a viscous form if it is reheated. In other implementations, at least one of the skin panels 200 can be a cured composite skin panel.

[0052] The skin panel 200 may also include reinforcing fibers. The reinforcing fibers of the skin panel 200 may include one or more of carbon fiber, glass fiber, aramid fiber, or combinations thereof.

[0053] Although Figure 1The skin panel 200 is shown as generally flat, but this disclosure is not limited thereto. In some implementations, the skin panel 200 may have a curved and / or highly wavy shape. The foam core 300 may also have a curved or highly wavy shape and / or may conform to the curved or highly wavy shape of the skin panel 200 when it expands. As used herein, the term “highly wavy” refers to one or more curvatures having a radius of 100 inches or less along at least one of the x, y, or z axes. For example, a highly wavy shape may include any radius of curvature less than 12 inches along at least one of the x, y, or z axes.

[0054] The foam core 300 may include an expandable or foamable material that starts in an unexpanded state and expands, enlarges, or swells in response to a predetermined change in conditions or a triggering event. For example, the foam core 300 may include expandable spheres, beads, powders, wet foam, etc., configured to expand in volume in response to changes in temperature, pressure, chemical reactions, and / or the input of radiant energy (e.g., UV light exposure). The expandable material of the foam core 300 may be configured to expand at room temperature.

[0055] The foam core 300 may have an average height of about 0.05 inches to about 5 inches. For example, the foam core 300 may have an average height of about 0.50 inches to about 4 inches, about 0.50 inches to about 3 inches, or about 0.50 inches. The height of the foam core 300 may correspond to a predetermined distance as described below.

[0056] In some implementations, the reinforced sandwich panel 10 also includes a flexible film 150. The flexible film 150 can be implemented as a pleated or expandable bag. Figures 8 to 10 As shown, the foam core 300 can be encapsulated by a flexible membrane 150. The flexible membrane 150 is configured to expand as the expandable material of the foam core 300 expands. The flexible membrane 150 may include one or more of polyolefins, polyesters, polystyrene, polyvinyl chloride (PVC), polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF), PA, TPU, or combinations thereof. In some implementations, high-strength membranes such as PEEK and PEKK are too rigid to be sufficiently stretched and cannot be used in the flexible membrane 150. Therefore, in some implementations, the flexible membrane does not include PEEK and PEKK.

[0057] The flexible membrane 150 can be configured to improve the thermal conductivity and / or electrical conductivity of the foam core 300 and / or the reinforced sandwich panel 10. For example, the flexible membrane 150 may include a conductive material to improve the thermal conductivity and / or electrical conductivity of the foam core 300 and / or the reinforced sandwich panel 10. For example, the flexible membrane 150 can enhance the electrical conductivity of the reinforced sandwich panel 10 to strengthen electromagnetic damage protection, such as lightning protection. By increasing the electrical conductivity of the reinforced sandwich panel 10, the electromagnetic effects (EME) resistance of an aircraft including one or more reinforced sandwich panels 10 is enhanced.

[0058] The flexible membrane 150 may include a thermosetting membrane adhesive configured to cure and / or bond the foam core 300 to at least one of the skin panel 200 or the expandable frame 400 in response to the expansion of the expandable material of the foam core 300. For example, the flexible membrane 150 may bond the foam core 300 to at least one of the skin panel 200 or the expandable frame 400. In some implementations, the flexible membrane 150 bonds the foam core 300 to the skin panel 200. The flexible membrane 150 may include a thermoplastic or thermosetting material configured to melt or degrade in response to the expansion of the expandable material of the foam core 300. For example, the flexible membrane 150 may degrade as the expandable material expands, allowing the expandable material to expand around the expandable frame 400 and / or within substantially the entire infillable cavity 450. The flexible membrane 150 may be stitched in a pattern to enhance in-plane uniformity and facilitate uniform expansion of the expandable material. For example, the flexible membrane 150 can be sewn together with the expandable material of the foam core 300.

[0059] like Figures 9 to 10 As shown, the foam core 300 may include one or more foam cores 300. Each of the one or more foam cores 300 may be encapsulated by a separate flexible membrane 150. The one or more foam cores 300 may be as follows: Figures 9 to 10 The arrangement can be horizontal, or it can be arranged vertically.

[0060] The foam core 300 may include a polymer matrix configured to retain a blowing agent. For example... Figure 8 As shown, the foam core 300 can be implemented as a plurality of expandable spheres 100, which include a polymer matrix for retaining the blowing agent. Figure 8 As shown, the expandable spheres 100 can be evenly distributed among the skin panels 200 after expansion to form a consistent foam core 300.

[0061] When heated to at least a predetermined temperature or in response to a predetermined change in conditions or a triggering event, the foaming agent can form multiple pores, cavities, or voids within the polymer matrix to increase its volume.

[0062] The polymer matrix may include one or more of thermoplastic polymers, thermosetting polymers, epoxy polymers, silicone resins, polyurethanes, rubbers, or combinations thereof.

[0063] The polymer matrix may include phenolic resin, epoxy resin, polystyrene (PS), polyethylene (PE), polypropylene (PP), polyamide (PA), polyethylene terephthalate (PET), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polycarbonate (PC), polyetherimide (PEI), polyphenylene sulfone (PPSU), thermoplastic polyurethane (TPU), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethane (PU), polyvinylidene fluoride (PVDF), or combinations thereof.

[0064] In some implementations, the polymer matrix comprises a high-temperature thermoplastic polymer. In other implementations, the polymer matrix comprises a low-temperature thermoplastic polymer. For example, the polymer matrix may include at least one of PET, PS, PEI, PU, ​​PPSU, or combinations thereof. The polymer matrix may be at least one of PEI or PU.

[0065] The polymer matrix can be configured not to melt during the curing process. Therefore, in some implementations, the melting point of the polymer matrix is ​​higher than the maximum curing temperature, such as the curing temperature of the skin panel 200. For example, the polymer matrix may have a melting temperature of at least 150°F, at least 200°F, at least 300°F, or at least 350°F. In other implementations, the polymer matrix may have a melting temperature from about 50°F to about 850°F, from about 100°F to about 600°F, or from about 200°F to about 400°F. In some implementations, the melting point of the polymer matrix is ​​lower than the melting point of the skin panel 200. Similarly, the melting point of the foam core 300 may be lower than the melting point of the skin panel 200.

[0066] Foam core 300 can be fused to two skin panels 200. As used herein, the term "fusion" means bonding substrates without any additional intermediate layers, such as adhesive layers designed to bond substrates. For example, skin panel 200 may include uncured composite skin panel or prepreg, and foam core 300 may be fused to skin panel 200 during the curing of the uncured shin panel.

[0067] A blowing agent may include a gas or liquid configured to react in response to a predetermined change in conditions or a triggering event. The blowing agent may be a gas or liquid, such as carbon dioxide, nitrogen, one or more hydrocarbons, water, and / or any other suitable physical and / or chemical blowing agent configured to react in response to a predetermined change in conditions or a triggering event. In other implementations, the blowing agent may include a gas, powder, supercritical gas, and / or other components configured to react in response to a predetermined change in conditions or a triggering event. A blowing agent may include only one gas, one solid, or one liquid. A blowing agent may include a combination of gas, solid, or liquid, or a combination of gas, solid, and liquid. A blowing agent may include one or more of physical blowing agents, chemical blowing agents, or combinations thereof.

[0068] Foaming agents may include physical foaming agents configured to expand according to physical reactions (such as thermal expansion). Foaming agents may include one or more of chlorofluorocarbons (CFCs), hydrochlorofluorocarbons (HCFCs), hydrofluorocarbons (HFCs), hydrocarbons such as propane, isobutane, pentane, ethanol, water vapor, carbon dioxide (CO2), nitrogen (N2), helium, or combinations thereof.

[0069] Foaming agents may include chemical foaming agents configured to generate expanding gas according to a chemical reaction. Foaming agents may include one or more of benzenesulfonyl hydrazine, toluenesulfonyl-aminourea, 5-phenyltetraazole, dinitrobenzopentamethyltetramine, sodium bicarbonate, citric acid, or combinations thereof. Foaming agents may also include one or more of isocyanates, azodicarbonamide, hydrazine, toluenesulfonyl-aminourea, or combinations thereof.

[0070] In other implementations, the foam core 300 includes a wet foam configured to expand according to a chemical or physical reaction. For example, the foam core 300 may include a wet form of a foamable material capable of flowing in a certain way and filling irregular shapes, such as a paste activated to expand, a two-part liquid mixture, etc. The wet foam may be a multi-part system configured for room-temperature activation. The wet foam may also be configured to activate in response to a predetermined change in conditions or a triggering event, such as a change in temperature, pressure, or a chemical reaction.

[0071] For example, the foam core 300 may include wet foam, and the wet foam may include a two-part system that is mixed together to activate foaming and expand at room temperature, such as a polyurethane foam system.

[0072] The foam core 300 may include a polyurethane foaming system.

[0073] The foam core 300 may include one or more layers of expandable material. The foam core 300 may include one or more additional layers 225. For example, such as... Figure 7As shown, the foam core 300 may include two expandable material layers 301 and 302. One or more expandable material layers 301 and 302 may include the same expandable material or may include different expandable materials. At least one of the one or more expandable material layers 301 and 302 may be encapsulated by a flexible membrane 150.

[0074] An additional layer 225 may be disposed between the two expandable material layers 301 and 302. The additional layer 225 may include at least one of reinforcing fibers or an adhesive layer. For example, the additional layer 225 may be implemented as a fiber shield including reinforcing fibers configured to increase the structural strength of the foam core 300. The additional layer 225 may be implemented as an adhesive layer configured to bond the two expandable material layers 301 and 302.

[0075] The foam core 300 may include reinforcing fibers. Reinforcing fibers can be used to increase the strength and stiffness of the foam core 300. Reinforcing fibers may include one or more of carbon fiber, glass fiber, aramid fiber, polyester fiber, hemp fiber, wood fiber, or combinations thereof. Other fibers that may be used include talc fiber, wollastonite fiber, metal fiber, aramid fiber, or combinations thereof. Reinforcing fibers can improve the thermal conductivity and / or electrical conductivity of the foam core 300.

[0076] The expandable frame 400 may include one or more expandable frames 400. The expandable frame 400 may be bonded to the skin panel 200. For example, the expandable frame 400 may be bonded to the skin panel 200 using an adhesive, such as a thermoplastic film layer designed to bond the expandable frame 400 to the skin panel 200.

[0077] In one implementation, the reinforced sandwich panel 10 includes one or more adhesive layers 500 disposed between the skin panel 200 and the expandable frame 400. The one or more adhesive layers 500 may be configured to bond the expandable frame 400 to the skin panel 200. In another implementation, the expandable frame 400 may be fused to the skin panel 200. For example, the skin panel 200 may include an uncured composite skin panel or prepreg, and the expandable frame 400 may be fused to the skin panel 200 during the curing of the uncured bonded panel. Fusion allows the uncured resin in the uncured composite skin or prepreg to act as a bonding adhesive. Therefore, the fusion of the skin panel 200 and the expandable frame 400 can occur simultaneously with the curing of the skin panel 200 at high temperatures. This avoids the need for additional adhesive layers, resulting in better bonding and reduced release of volatile organic compounds (VOCs).

[0078] The expandable frame 400 is configured to separate the skin panels 200 by a predetermined distance. For example, as... Figures 4 to 5As shown, the expandable frame has a first height 41 that separates the skin panel 200 when the expandable frame 400 is in a contracted state, and a second height 42 that separates the skin panel 200 when the expandable frame 400 is in an expanded state. The second height 42 is greater than the first height 41.

[0079] When the expandable frame 400 is in an expanded state, the infillable cavity 450 can be defined between the skin panels 200. The infillable cavity 450 can have a height corresponding to a predetermined distance. For example, the infillable cavity 450 can have a height corresponding to a second height 42. The expandable material of the foam core 300 can be disposed within the infillable cavity 450. The expandable frame 400 can be configured to maintain a predetermined distance separated from the skin panels 200 when the infillable cavity is filled with the expandable material.

[0080] When the reinforced sandwich panel 10 is subjected to a vacuum, the expandable frame 400 can maintain a second height 42 separating the skin panel 200 when the expandable frame 400 is in an expanded state.

[0081] A desirable feature of this disclosure is the ability to control the thickness of the foam core 300 by controlling a predetermined distance. For example... Figure 7 As shown, the distance between the skin panels 200 determines the thickness of the foam core 300. A second height 42 can correspond to the thickness of the foam core 300. For example, the distance between the skin panels 200 can constrain the expansion of the foam core 300 and / or determine the thickness of the foam core 300.

[0082] The expandable frame 400 can be elastic and / or flexible. For example, as... Figures 4 to 5 As shown, the expandable frame 400 can elastically expand from a contracted state having a first height 41 to an expanded state having a second height 42. In one implementation, the expandable frame 400 is biased toward the expanded state having the second height 42 in order to maintain the expandable frame 400 in the expanded state.

[0083] The expandable frame 400 may include a plurality of interconnected and expandable struts 401. For example, the expandable frame 400 may include a plurality of interconnected and expandable struts 401 configured to expand from a contracted state having a first height 41 to an expanded state having a second height 42. In some implementations, the plurality of interconnected and expandable struts 401 are configured to lock in the expanded state to maintain the expandable frame 400 in the expanded state. In other implementations, the plurality of interconnected and expandable struts 401 are configured to lock in at least one of a contracted state and an expanded state. The contracted state facilitates transport by minimizing the size of the reinforced mezzanine panel frame 12. The expanded state facilitates installation by maintaining the expandable frame 400 in the expanded state during a filling operation.

[0084] The expandable frame 400 can be configured to attract the foam core 300. For example, the expandable frame 400 generates a static field capable of attracting the expandable material of the foam core 300. The expandable frame 400 can be configured to attract and / or trap the expandable material of the foam core 300, thereby enhancing the uniform distribution of the expandable material, especially when the expandable material comprises spheres and / or powder. The uniform distribution of the expandable material enhances the uniform expansion of the expandable material and the uniform formation of the foam core 300.

[0085] Multiple interconnected and expandable pillars 401 can generate a static field capable of attracting the expandable material of the foam core 300.

[0086] The expandable frame 400 can be configured not to form isolated cavities when in an expanded state. For example, the expandable frame 400 may have a structure designed to prevent areas from being filled by the expandable material of the foam core 300 when it expands. Therefore, when the expandable frame 400 is in an expanded state, the fillable cavity 450 can be in complete liquid communication.

[0087] The expandable frame 400 may include one or more of the following: metal, ceramic, paper or fiber products, thermoplastic materials, thermosetting materials, or combinations thereof. For example, the expandable frame 400 may include one or more of the following: phenolic plastics, epoxy resins, polypropylene (PP), polyamide (PA), polyethylene terephthalate (PET), polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polycarbonate (PC), polyetherimide (PEI), polyphenylene sulfone (PPSU), thermoplastic polyurethane (TPU), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethane (PU), or combinations thereof. The expandable frame 400 may also include paper or fiber products, such as Nomex.

[0088] The expandable frame 400 may have a higher melting temperature than the curing temperature of at least one of the skin panels 200. The expandable frame may have a higher melting temperature than at least one of the curing temperature or the melting temperature of the foam core 300. For example, the expandable frame 400 may be used as a skeleton for the foam core 300, and the higher melting temperature ensures that the integrity of the expandable frame 400 is maintained during the curing process, and that neither the expandable frame 400 nor the foam core 300 collapses.

[0089] The expandable frame 400 can improve the thermal and / or electrical conductivity of at least one of the foam core 300 or the reinforced sandwich panel 10. For example, the expandable frame 400 can serve as a heat transfer path and / or an electrical path to enhance the thermal and / or electrical conductivity of the foam core 300. In some implementations, the foam core 300 can be configured to have low thermal and / or low electrical conductivity. For other implementations, such heat transfer and / or electrical paths in the core matrix are important, for example, when lightning may potentially occur.

[0090] One or more adhesive layers 500 may include epoxy resin, epoxy resin film, paste, adhesive, plastic film such as polyethylene terephthalate or polyester (PET) film, polyimide (PI) film, polyphenylene sulfone (PPSU) film, polymethyl methacrylate (PMMA) film, or other types of materials configured to bond a substrate. One or more adhesive layers 500 may bond at least one of the expandable frame 400 or the foam core 300 to the skin panel 200. One or more adhesive layers 500 may bond the flexible film 150 to the skin panel 200.

[0091] Figure 2 An enhanced multi-core sandwich panel according to an implementation of the present disclosure is shown. Figure 2 An enhanced multi-core sandwich panel is shown, which may use a foam core 300 and / or an expandable frame 400, as described above. Figure 1 Other components of the reinforced sandwich panel 10 are shown. Therefore, the following discussion will refer to... Figure 1 The various components shown.

[0092] like Figure 2 As shown, the reinforced multi-core sandwich panel 11 may include two or more skin panels 200 and two or more foam cores 320 disposed between the two or more skin panels 200. Having two or more foam cores 320 allows the reinforced multi-core sandwich panel 11 to simultaneously perform multiple functions. For example, the first foam core 320 may include an open-cell flexible foam core layer to reduce sound, and the second foam core 320 may include a closed-cell rigid foam core to enhance flame retardancy as well as overall strength and stiffness.

[0093] Two or more foam cores 320 may comprise sandwich cores of known types, such as honeycomb cores, solid foam cores, or machined foam cores. Two or more foam cores 320 may comprise solid composite laminates. At least one of the two or more foam cores 320 may comprise a vacuum insulation layer. The vacuum insulation layer can significantly enhance the thermal and acoustic insulation properties of the foam core 320. The vacuum insulation layer can be formed by evacuating a vacuum between two or more skin panels 200, by evacuating a vacuum after the open-cell rigid foam core 320 has been formed and then sealing it, or the vacuum insulation layer may comprise a prefabricated vacuum panel forming the foam core 320.

[0094] Two or more foam cores 320 may include foam cores 300 as described above. At least one of the two or more foam cores 320 is a foam core 300 having an expandable frame 400 disposed therein.

[0095] The foam core 300 may include one or more expandable material layers, and the one or more expandable material layers may be separated by one or more additional layers 225.

[0096] Two or more foam cores 320 may be separated by one or more intermediate skins or diaphragms 201. For example, this can be achieved by separating a more rigid foam core 320 at the center of the reinforced multicore sandwich panel 11 from a more flexible foam core 320 at the edges of the reinforced multicore sandwich panel 11. The diaphragm 201 can increase the stiffness, strength, or rigidity of the entire reinforced multicore sandwich panel 11. In some implementations, the diaphragm 201 can provide attachment points for the foam cores 320.

[0097] Therefore, each of two or more foam cores 320 will be disposed between two skin panels 200, between a skin panel 200 and a diaphragm 201, or between two diaphragms 201. For example, as Figure 2 As shown, the reinforced multi-core sandwich panel 11 may include one or more diaphragms 201 disposed between two or more foam cores 320. Figure 2 As shown, foam cores 320 are disposed between two diaphragms 201, and each of the foam cores 300 is disposed between a skin panel 200 and a diaphragm 201. Diaphragms 201 may comprise the same material as the two skin panels 200. In other implementations, diaphragms 201 may comprise one or more of the following: fiber-reinforced laminates, thermosetting materials (epoxy resins, phenolic plastics, etc.), thermoplastic solid sheets, thermoplastic foam boards, or combinations thereof. Long fiber-reinforced composite sheets in diaphragms 201 may provide stiffness or strength to reinforce the multi-core sandwich panel 11, or may allow the sheets to be delaminated to form diaphragms 201. Diaphragms 201 comprising porous foam or solid materials may provide controlled flow barriers for separating the foam cores 320.

[0098] The reinforced multi-core sandwich panel 11 may include one or more adhesive layers 500. One or more adhesive layers 500 may be disposed between two or more foam cores 320 and two or more skin panels 200 or one or more diaphragms 201. The one or more adhesive layers 500 bond at least one of the two or more foam cores 320 to the two or more skin panels 200 or one or more diaphragms 201. For example, one or more adhesive layers 500 may bond at least one of a foam core 300 and an expandable frame 400 to the two or more skin panels 200 or one or more diaphragms 201.

[0099] At least one of the foam core 300 and the expandable frame 400 is attached to at least one of two or more skin panels 200. For example, the expandable frame 400 of the foam core 300 is bonded to two or more skin panels 200 or to one or more diaphragms 201 surrounding the foam core 300. In one implementation, at least one of the foam core 300 and the expandable frame 400 is fused to at least one of two or more skin panels 200. For example, at least one of the foam core 300 and the expandable frame 400 is fused to at least one of two or more skin panels 200 or to one or more diaphragms 201 surrounding the foam core 300.

[0100] At least one of the two or more foam cores 320 may have one or more functional properties that are different from the remaining foam cores 320. At least one of the two or more foam cores 320 may have one or more functional properties that are the same as the remaining foam cores 320. For example, functional properties may include flame retardancy, rigidity or stiffness, impact resistance, toughness, tensile strength, compressive strength, and flexural strength. The material or type of foam core 320 may determine one or more functional properties. For example, the expandable material of foam core 300 may determine one or more functional properties of foam core 300. In one implementation, the expandable material of at least one of the two or more foam cores 320 may be different from the expandable material of the remaining foam cores 320. For example, at least one of the two or more foam cores 320 may include one or more nanoporous foam layers to enhance the thermal insulation of the reinforced multi-core sandwich panel 11. At least one of the two or more foam cores 320 may include one or more open-cell foam layers to enhance the sound absorption performance of the reinforced multi-core sandwich panel 11. At least one of the two or more foam cores 320 may include one or more rigid materials, such as PEKK or PEEK, to increase the stiffness of the reinforced multi-core sandwich panel 11. At least one of the two or more foam cores 320 may include one or more flexible materials, such as TPU, to enhance the cushioning performance of the reinforced multi-core sandwich panel 11.

[0101] Figure 3 A method for manufacturing a reinforced sandwich panel frame according to an implementation of the present disclosure is shown. Figures 4 to 5 An enhanced mezzanine panel frame according to an implementation of this disclosure is shown. Figures 4 to 5 As shown, the reinforced mezzanine panel frame 12 includes two skin panels 200 (210 and 220) and an expandable frame 400. The expandable frame 400 may include one or more expandable frames 400. Figures 4 to 5 As shown, the reinforced sandwich panel frame 12 may also include one or more adhesive layers 500 (510 and 520).

[0102] Figures 3 to 5 A method is shown, for example, that can be used to manufacture a reinforced sandwich panel frame 12 for the aforementioned reinforced sandwich panel 10 or reinforced multi-core sandwich panel 11. Therefore, the following discussion will refer to... Figures 1 to 5 The various components shown.

[0103] like Figures 3 to 5 As shown, the method 800 for manufacturing the reinforced sandwich panel frame 12 begins in operation 810 by placing the first skin panel 210.

[0104] Operation 820 includes placing the expandable frame 400 onto the first skin panel 210. In some implementations, the reinforced sandwich panel frame 12 includes a first adhesive layer 510. For example, the reinforced sandwich panel frame 12 may include a first adhesive layer 510 between the expandable frame 400 and the first skin panel 210. Therefore, placing the expandable frame 400 onto the first skin panel 210 may include placing the first adhesive layer 510 onto the first skin panel 210, and placing the expandable frame 400 onto the first adhesive layer 510. The first adhesive layer 510 may bond the expandable frame 400 to the first skin panel 210.

[0105] Operation 830 includes placing the second skin panel 220 onto the expandable frame 400. In some implementations, the reinforcing sandwich panel frame 12 includes a second adhesive layer 520. For example, the reinforcing sandwich panel frame 12 may include a second adhesive layer 520 between the expandable frame 400 and the second skin panel 220. Therefore, placing the second skin panel 220 onto the expandable frame 400 may include placing the second adhesive layer 520 onto the second skin panel 220, and placing the second skin panel 220 onto the expandable frame 400. The second adhesive layer may bond the expandable frame 400 to the second skin panel 220.

[0106] Operation 840 includes attaching the expandable frame 400 to the first skin panel 210 and the second skin panel 220.

[0107] In some implementations, the reinforced sandwich panel frame 12 includes one or more adhesive layers 500 to bond the expandable frame 400 to the first skin panel 210 and the second skin panel 220, and operation 840 includes adhesively bonding the expandable frame 400 to the first skin panel 210 and the second skin panel 220. In other implementations, the first skin panel 210 and the second skin panel 220 include uncured composite skin panels or prepregs. Therefore, bonding the expandable frame 400 to the first skin panel 210 and the second skin panel 220 may include curing the first skin panel 210 and the second skin panel 220 in operation 840. Curing of the first skin panel 210 and the second skin panel 220 may fuse the expandable frame 400 to the first skin panel 210 and the second skin panel 220.

[0108] like Figures 4 to 5 As shown, the reinforced sandwich panel frame 12 includes an expandable frame 400. The expandable frame 400 is coupled to a first skin panel 210 and a second skin panel 220. The expandable frame 400 is configured to separate the first skin panel 210 and the second skin panel 220 by a predetermined distance. The predetermined distance may correspond to the thickness of the foam core 300 after its expansion. For example, as Figures 4 to 5 As shown, when the expandable frame 400 is in a retracted state, the expandable frame separates the first skin panel 210 and the second skin panel 220 by a first height 41, and when the expandable frame 400 is in an expanded state, the expandable frame separates the first skin panel 210 and the second skin panel 220 by a second height 42. The second height 42 may correspond to a predetermined distance.

[0109] In some examples, the reinforced sandwich panel frame 12 can keep the foam core 300 in a contracted state before it fully expands. For example, as... Figure 9 As shown, before the foam core 300 expands, one or more foam cores 300 can be placed in the reinforced sandwich panel frame 12 in a contracted state with a first height 41.

[0110] like Figure 5 As shown, when the expandable frame 400 is in an expanded state, the reinforced sandwich panel frame 12 defines an infillable cavity 450 between the first skin panel 210 and the second skin panel 220. The infillable cavity 450 may be configured to receive the foam core 300. The expandable frame 400 may be configured to maintain the first skin panel 210 and the second skin panel 220 separated by a predetermined distance when the infillable cavity is filled. The predetermined distance may correspond to the final thickness of the foam core 300 after its expansion.

[0111] Figure 6A method for manufacturing a reinforced sandwich panel according to an implementation of the present disclosure is shown. Figures 7 to 10 The implementation of a method for manufacturing reinforced sandwich panels is shown. Figure 6 A method is shown, for example, that can be used to manufacture a reinforced sandwich panel 10 or a reinforced multi-core sandwich panel 11 using the aforementioned reinforced sandwich panel frame 12. Therefore, the following discussion will refer to... Figures 1 to 10 The various components shown.

[0112] like Figure 6 As shown, a method 900 for manufacturing a reinforced sandwich panel 10 begins in operation 910 by placing a reinforced sandwich panel frame 12. Placing the reinforced sandwich panel frame 12 may include placing the reinforced sandwich panel frame 12 at the location where the reinforced sandwich panel 10 will be mounted. For example, the reinforced sandwich panel 10 may be placed at the final location where it will ultimately be mounted.

[0113] In method 900, the reinforced sandwich panel 10 can be formed on-site. For example, the foam core 300 can be installed and expanded within the reinforced sandwich panel frame 12 at the location or place where the reinforced sandwich panel 10 will ultimately be placed. This eliminates the additional process steps of manufacturing the foam core 300 separately from the reinforced sandwich panel frame 12. Furthermore, because the reinforced sandwich panel frame 12 can be transported in a collapsed state, method 900 eliminates the logistical and transportation costs of transporting the completed reinforced sandwich panel 10, which already includes the expanded foam core 300.

[0114] Another feature of method 900 is that the expandable material of the foam core 300 can be foamable. That is, it can occupy a small space or volume before expansion, thereby facilitating the transport and storage of the reinforced sandwich panel 10 and / or the reinforced sandwich panel frame 12. For example, the expandable material of the foam core 300 can be 1 mm thick before expansion or foaming, and can be 10 mm thick after expansion, thus saving a significant amount of space for transport and storage, especially when combined with the expandable frame 400.

[0115] In another implementation, placing the reinforced sandwich panel frame 12 may include placing the reinforced sandwich panel frame 12 within the forming tool 700. For example... Figure 8 As shown, the forming tool 700 can be configured to hold the reinforced sandwich panel frame 12 during the installation and expansion of the foam core 300. For example, a first tool member 710 can be configured to hold a first skin panel 210, and a second tool member 720 can be configured to hold a second skin panel 220.

[0116] Operation 920 includes expanding the reinforced sandwich panel frame 12, which may include expanding the reinforced sandwich panel frame 12 to separate the first skin panel 210 and the second skin panel 220 by a predetermined distance, such as a second height 42. The second height 42 may correspond to the thickness of the foam core 300.

[0117] like Figures 4 to 5 As shown, the expandable frame 400 can be elastic and / or flexible, and the expandable frame 400 can elastically expand the reinforced sandwich panel frame 12 from a contracted state having a first height 41 to an expanded state having a second height 42. Therefore, expanding the reinforced sandwich panel frame 12 can include using the expandable frame 400 to elastically expand the reinforced sandwich panel frame 12 to an expanded state. In one implementation, the reinforced sandwich panel frame 12 expands to the expanded state solely due to the elastic force of the expandable frame 400. For example, the reinforced sandwich panel frame 12 can expand to the expanded state without any external force. The expandable frame 400 can be configured to lock in the expanded state to maintain a predetermined distance between the first skin panel and the second skin panel. In one implementation, the expandable frame 400 is locked in the expanded state to maintain a predetermined distance between the skin panels 200 of the reinforced sandwich panel frame 12.

[0118] In another implementation, the reinforced sandwich panel frame 12 can be expanded to an expanded state by external force. For example, as... Figure 8 As shown, the reinforced sandwich panel frame 12 can be placed within a forming tool 700, and the forming tool 700 can be used to inflate the reinforced sandwich panel frame 12 to a predetermined distance between the first skin panel and the second skin panel. In one implementation, the first tool member 710 is a first forming tool, the second tool member 720 is a second forming tool, and the first tool member 710 and the second tool member 720 are configured to hold the first skin panel 210 and the second skin panel 220, and at least one of the first tool member 710 and the second tool member 720 is configured to move to separate the first skin panel 210 and the second skin panel 220 to a predetermined distance. Therefore, inflating the reinforced sandwich panel frame 12 can include using the forming tool 700 to inflate the reinforced sandwich panel frame 12 to an inflated state.

[0119] In another implementation, as described below, the reinforced sandwich panel frame 12 can be expanded to an expanded state by the expansion of the foam core 300. Therefore, expanding the reinforced sandwich panel frame 12 can include expanding the foam core 300 to expand the reinforced sandwich panel frame 12 to an expanded state.

[0120] Operation 930 includes placing the foam core 300 within the reinforced sandwich panel frame 12. For example, as... Figures 4 to 5As shown, when the reinforced sandwich panel frame 12 is in an expanded state, the fillable cavity 450 is defined between the first skin panel 210 and the second skin panel 220. Placing the foam core 300 within the reinforced sandwich panel frame 12 may include placing the foam core 300 within the fillable cavity 450 of the reinforced sandwich panel frame 12. The foam core 300 may be encapsulated by a flexible membrane 150.

[0121] like Figure 9 As shown, in other implementations, placing the foam core 300 within the reinforced sandwich panel frame 12 may include placing the foam core 300 within the reinforced sandwich panel frame 12 when the foam core 300 is in a contracted state. As described above, placing the unexpanded foam core 300 within the reinforced sandwich panel frame 12 facilitates its transport to the installation site.

[0122] like Figure 7 As shown, the foam core 300 may include one or more expandable material layers. For example, the foam core 300 may include two expandable material layers 301 and 302 separated by an additional layer 225.

[0123] like Figure 8 As shown, the foam core 300 may include a plurality of expandable spheres 100 encapsulated by a flexible membrane 150.

[0124] like Figures 9 to 10 As shown, the foam core 300 may include one or more foam cores 300. Each of the one or more foam cores 300 may be encapsulated by a flexible membrane 150.

[0125] In some implementations, the reinforced sandwich panel frame 12 includes one or more adhesive layers 500, and the foam core 300 can be placed on one or more adhesive layers 500. For example, as Figure 9 As shown, one or more foam cores 300 may be placed on at least one of the first adhesive layer 510 or the second adhesive layer 520. The first adhesive layer 510 and the second adhesive layer 520 may hold one or more foam cores 300 within the reinforced sandwich panel frame 12 before the foam cores 300 expand. For example, the first adhesive layer 510 and the second adhesive layer 520 may hold one or more foam cores 300 during transport of the reinforced sandwich panel frame 12.

[0126] Operation 940 includes expanding the foam core 300. As described above, the expandable material of the foam core 300 can expand in response to a predetermined change in conditions or a triggering event. In some implementations, the expandable material of the foam core 300 is configured to expand at room temperature. Therefore, expanding the foam core 300 can include activating the expandable material of the foam core 300. The foam core 300 can expand until it reaches a thickness corresponding to a predetermined distance. For example, as... Figures 9 to 10 As shown, the foam core 300 expands until it reaches a height of 42. (As indicated) Figures 9 to 10 As shown, in some implementations, the expansion of the foam core 300 can cause the reinforced sandwich panel frame 12 to expand to an expanded state. The expandable frame 400 can be configured to prevent the expansion of the foam core 300 from exceeding the second height 42 and / or a predetermined distance. The foam core 300 can expand to fill substantially all of the infillable cavity 450.

[0127] Method 900 may further include reinforcing the sandwich panel 10 in operation 950. For example, after the foam core 300 expands, the reinforcing sandwich panel frame 12 may form the reinforcing sandwich panel 10. Figure 7 As shown, the reinforced sandwich panel 10 may include placing a vacuum bag 600 around the reinforced sandwich panel 10 and applying a vacuum to the reinforced sandwich panel 10.

[0128] At least one of the skin panels 200 (210 or 220) may include an uncured composite skin panel or prepreg, and the reinforced sandwich panel 10 may include applying either a curing pressure or a temperature to the reinforced sandwich panel 10. In some implementations, curing of the skin panel 200 may be used to fuse at least one of the expandable frame 400 or the foam core 300 to at least one of the skin panels 200 (210 or 220).

[0129] Method 900 may also include trimming the reinforced sandwich panel 10 in operation 960. For example, if excess expandable material of the foam core 300 protrudes between the first skin panel 210 and the second skin panel 220, it may be trimmed. Trimming the reinforced sandwich panel 10 may include cutting the reinforced sandwich panel 10 into a desired shape and / or size.

[0130] Method 900 may further include sealing the reinforced sandwich panel 10 in operation 970. For example, the reinforced sandwich panel 10 may be coated with a resin coating 630 (not shown). Sealing the reinforced sandwich panel 10 may include edge sealing of the reinforced sandwich panel 10. For example, a sealant, such as epoxy resin, may be applied to the edges of the reinforced sandwich panel 10.

[0131] Method 900 may also include removing the reinforcing sandwich panel 10 in operation 980. For example, after the foam core 300 expands, it can be removed from... Figure 8 The forming tool 700 shown removes the reinforcing sandwich panel 10. In some implementations, the reinforcing sandwich panel 10 is cooled before removal. Removal of the reinforcing sandwich panel 10 may include known techniques, such as applying a release agent and / or cooling at a certain rate, to ensure that the reinforcing sandwich panel 10 does not stick to the forming tool 700 and / or is easily removed.

[0132] The implementation of this disclosure can be used in a variety of potential applications, particularly in the transportation industry, including applications such as aerospace, marine, automotive, and other applications requiring reinforced sandwich panels. Therefore, reference is now made to... Figure 11 and Figure 12 The implementation of this disclosure can be used for, for example Figure 11 The aircraft manufacturing and maintenance methods 1000 and as shown Figure 12 The illustrated environment of aircraft 2000. During pre-production, exemplary methods may include the specification and design of aircraft 2000 and material procurement 1104. During the production process 1106 (e.g., component and / or sub-component manufacturing), system integration of aircraft 2000 is performed 1108. Subsequently, aircraft 2000 may undergo certification and delivery 1110 for entry into service 1112. When used by a customer, aircraft 2000 is scheduled for routine maintenance and repair 1114, which may also include modifications, remodeling, refurbishment, etc.

[0133] Each of the steps in Method 1000 can be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator can include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party can include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator can be an airline, leasing company, military entity, maintenance organization, etc.

[0134] like Figure 12 As shown, an aircraft 2000 produced by the exemplary method 1000 may include a fuselage 2115 and an interior 2120 having multiple systems 2118. Examples of systems 2118 include one or more of a propulsion system 2122, an electrical system 2124, a hydraulic system 2126, and an environmental system 2128. Any number of other systems may be included. Although an aerospace example is shown, the principles of this disclosure can be applied to other industries, such as the marine and automotive industries.

[0135] During any one or more stages of the aircraft manufacturing and maintenance method 1000, the systems and methods illustrated herein may be employed. For example, a component or sub-assembly corresponding to production process 1106 may be manufactured or produced in a manner similar to that of a component or sub-assembly produced when the aircraft 2000 is in service. Moreover, one or more equipment examples, method examples, or combinations thereof may be used during production processes 1106 and 1108, for example, by sufficiently accelerating the assembly of the aircraft 2000 or reducing its cost. Similarly, one or more of the equipment examples, method examples, or combinations thereof may be utilized when the aircraft 2000 is in service, for example, but not limited to, maintenance and repair 1114.

[0136] Although Figure 11 and Figure 12 This disclosure is described for illustrative purposes with respect to aircraft and aircraft manufacturing and maintenance, but it is not limited thereto. The systems and methods of this disclosure can also be used with spacecraft, satellites, submarines, surface vessels, automobiles, tanks, trucks, power plants, and any other suitable objects.

[0137] Furthermore, this disclosure includes examples pursuant to the following terms:

[0138] Clause 1. A reinforced sandwich panel comprising: two skin panels; a foam core disposed between the two skin panels; and an expandable frame disposed within the foam core.

[0139] Clause 2. The reinforced sandwich panel of Clause 1, the reinforced sandwich panel further comprising one or more adhesive layers, wherein the one or more adhesive layers bond at least one of the foam core and the expandable frame to the two skin panels.

[0140] Clause 3. The reinforced sandwich panel of Clause 1 or 2, the reinforced sandwich panel further comprising a flexible membrane, wherein the foam core is encapsulated by the flexible membrane, and wherein the flexible membrane binds the foam core to at least one of the skin panel or the expandable frame.

[0141] Clause 4. A reinforced sandwich panel of any one of Clauses 1 to 3, wherein the foam core comprises one or more expandable material layers and one or more additional layers, and wherein the one or more additional layers comprise at least one of reinforcing fibers or adhesive layers.

[0142] Clause 5. A reinforced mezzanine panel of any one of Clauses 1 to 4, wherein an expandable frame is incorporated into two skin panels, wherein the expandable frame separates the skin panels by a predetermined distance.

[0143] Clause 6. The reinforced mezzanine panel of Clause 5, wherein the expandable frame elastically expands from a contracted state to an expanded state, and wherein the expandable frame is biased toward the expanded state, wherein the expandable frame includes a plurality of interconnected and expandable struts configured to expand from a contracted state to an expanded state, and wherein the plurality of interconnected and expandable struts are configured to lock in at least one of the contracted state and the expanded state.

[0144] Clause 7. A reinforced sandwich panel of any one of Clauses 1 to 6, wherein the expandable frame comprises one or more of metal, ceramic, paper or fiber products, thermoplastic materials, thermosetting materials, or combinations thereof.

[0145] Clause 8. A reinforced sandwich panel of any one of Clauses 1 to 7, wherein the expandable frame improves the thermal or electrical conductivity of at least one of the foam core or the reinforced sandwich panel.

[0146] Clause 9. A reinforced multi-core sandwich panel comprising: two or more skin panels; and two or more cores disposed between the two or more skin panels; wherein at least one of the two or more cores comprises a foam core having an expandable frame disposed therein.

[0147] Clause 10. The reinforced multicore sandwich panel of Clause 9, the reinforced multicore sandwich panel further comprising: one or more diaphragms disposed between two or more cores.

[0148] Clause 11. The reinforced multicore sandwich panel of Clause 10, the reinforced multicore sandwich panel further comprising: one or more adhesive layers disposed between two or more cores and two or more skin panels or one or more diaphragms, wherein the one or more adhesive layers bond at least one of the two or more cores to the two or more skin panels or one or more diaphragms.

[0149] Clause 12. An enhanced multi-core sandwich panel of any one of Clauses 9 to 11, wherein at least one of two or more cores has functional characteristics different from the remaining cores of the two or more cores.

[0150] Clause 13. A method for manufacturing a reinforced sandwich panel frame, the method comprising: placing a first skin panel; placing an expandable frame on the first skin panel; placing a second skin panel on the expandable frame; and attaching the expandable frame to the first skin panel and the second skin panel, wherein the expandable frame has a first height separating the first skin panel and the second skin panel when the expandable frame is in a contracted state, and a second height separating the first skin panel and the second skin panel when the expandable frame is in an expanded state, and wherein the second height is greater than the first height.

[0151] Clause 14. A method for manufacturing a reinforced sandwich panel, the method comprising: placing a reinforced sandwich panel frame; inflating the reinforced sandwich panel frame; placing a foam core within the reinforced sandwich panel frame; and inflating the foam core, wherein the reinforced sandwich panel frame includes: two skin panels and an inflatable frame disposed between the two skin panels, and wherein the inflatable frame has a first height separating the skin panels when the inflatable frame is in a contracted state, and a second height separating the skin panels when the inflatable frame is in an inflated state, and wherein the second height is greater than the first height.

[0152] Clause 15. The method of Clause 14, further comprising at least one of the following steps: reinforcing the reinforced sandwich panel; trimming the reinforced sandwich panel; sealing the reinforced sandwich panel; and removing the reinforced sandwich panel.

[0153] Clause 16. The method of Clause 14 or 15, wherein inflating the reinforced mezzanine panel frame includes using an inflatable frame to elastically inflate the reinforced mezzanine panel frame to an inflated state.

[0154] Clause 17. The method of any one of Clauses 14 to 16, wherein the expandable frame is locked in an expanded state to maintain a predetermined distance between the skin panels of the reinforced mezzanine panel frame.

[0155] Clause 18. The method of any one of Clauses 14 to 17, wherein inflating the reinforced sandwich panel frame comprises inflating the foam core to inflate the reinforced sandwich panel frame to an inflated state, wherein the expandable material of the foam core inflates at room temperature, and wherein the expandable frame generates a static field capable of attracting the expandable material of the foam core.

[0156] Clause 19. The method of any one of Clauses 15 to 18, wherein reinforcing the reinforced sandwich panel includes placing a vacuum bag around the reinforced sandwich panel and applying a vacuum to the reinforced sandwich panel.

[0157] Clause 20. The method of any one of Clauses 15 to 18, wherein reinforcing the reinforced sandwich panel includes applying one of curing pressure or temperature to the reinforced sandwich panel and fusing at least one of the frame or foam core to at least one of the skin panels.

[0158] This disclosure has been described with reference to exemplary implementations. Although some implementations have been shown and described, those skilled in the art will understand that changes can be made to these implementations without departing from the principles and spirit of the foregoing detailed description. This disclosure is intended to be construed as including all such modifications and changes, provided they fall within the scope of the appended claims or their equivalents.

Claims

1. A reinforced sandwich panel (10), the reinforced sandwich panel comprising: Two skin panels (200); A foam core (300) is disposed between the two skin panels (200); An expandable frame (400) disposed within the foam core (300), wherein the expandable frame (400) includes a plurality of interconnected and expandable pillars (401) configured to expand from a contracted state having a first height (41) to an expanded state having a second height (42); and A flexible membrane (150) is provided, wherein the foam core (300) is encapsulated by the flexible membrane (150), and wherein the flexible membrane (150) binds the foam core (300) to at least one of the skin panel (200) or the expandable frame (400). When the expandable frame (400) is in the expanded state, a fillable cavity (450) is defined between the two skin panels (200). The fillable cavity (450) is configured to receive the foam core (300). The expandable frame (400) is configured to maintain the two skin panels (200) separated by a predetermined distance when the fillable cavity is filled. The plurality of interconnected and expandable pillars are configured to lock in at least one of the contracted state and the expanded state.

2. The reinforced sandwich panel (10) according to claim 1, wherein the reinforced sandwich panel further comprises one or more adhesive layers (500), wherein, The one or more adhesive layers (500) bond at least one of the foam core (300) and the expandable frame (400) to the two skin panels (200).

3. A reinforced multi-core sandwich panel (11), the reinforced multi-core sandwich panel comprising: Two or more skin panels (200); as well as Two or more cores are disposed between the two or more skin panels (200); At least one of the two or more cores includes a foam core (300) having an expandable frame (400) disposed therein, wherein the expandable frame (400) includes a plurality of interconnected and expandable supports (401) configured to expand from a contracted state having a first height (41) to an expanded state having a second height (42). The reinforced multi-core sandwich panel further includes a flexible film (150), wherein the foam core (300) is encapsulated by the flexible film (150), and wherein the flexible film (150) binds the foam core (300) to at least one of the skin panel (200) or the expandable frame (400). When the expandable frame (400) is in the expanded state, a fillable cavity (450) is defined between the two or more skin panels (200), the fillable cavity (450) being configured to receive the foam core (300), and the expandable frame (400) being configured to maintain the two or more skin panels (200) separated by a predetermined distance when the fillable cavity is filled. The plurality of interconnected and expandable pillars are configured to lock in at least one of the contracted state and the expanded state.

4. The reinforced multi-core sandwich panel (11) according to claim 3, wherein the reinforced multi-core sandwich panel further comprises: One or more diaphragms (201) are disposed between the two or more cores.

5. The reinforced multi-core sandwich panel (11) according to claim 4, wherein the reinforced multi-core sandwich panel further comprises: One or more adhesive layers (500) are disposed between the two or more cores and the two or more skin panels (200) or between the two or more cores and the one or more diaphragms (201), wherein the one or more adhesive layers (500) bond at least one of the two or more cores to the two or more skin panels (200) or to the one or more diaphragms (201).

6. A method (900) for manufacturing a reinforced sandwich panel (10), the method comprising: Place the reinforced mezzanine panel frame (12); The reinforced sandwich panel frame (12) is expanded; Place the foam core (300) inside the reinforced sandwich panel frame (12); as well as The foam core (300) is expanded. The reinforced sandwich panel frame (12) includes: Two skin panels (200); An expandable frame (400) disposed between the two skin panels (200), wherein the expandable frame (400) includes a plurality of interconnected and expandable struts (401), and has a first height (41) separating the skin panels (200) when the expandable frame (400) is in a retracted state, and a second height (42) separating the skin panels (200) when the expandable frame (400) is in an expanded state, wherein the second height (42) is greater than the first height (41); and A flexible membrane (150) is provided, wherein the foam core (300) is encapsulated by the flexible membrane (150), and wherein the flexible membrane (150) binds the foam core (300) to at least one of the skin panel (200) or the expandable frame (400). When the expandable frame (400) is in the expanded state, a fillable cavity (450) is defined between the two skin panels (200). The fillable cavity (450) is configured to receive the foam core (300). The expandable frame (400) is configured to maintain the two skin panels (200) separated by a predetermined distance when the fillable cavity is filled. The plurality of interconnected and expandable pillars are configured to lock in at least one of the contracted state and the expanded state.

7. The method (900) according to claim 6, further comprising at least one of the following steps: Reinforce the reinforced sandwich panel (10); Trim the reinforced sandwich panel (10); Seal the reinforced sandwich panel (10); and Remove the reinforced mezzanine panel (10).

8. The method (900) according to claim 7, wherein, Inflating the reinforced sandwich panel frame (12) includes inflating the foam core (300) to inflate the reinforced sandwich panel frame (12) to an inflated state. The expandable material of the foam core (300) expands at room temperature, and The expandable frame (400) generates a static field that can attract the expandable material of the foam core (300).

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