Composite sandwich panels, cores for composite sandwich panels, methods of joining panels, and methods of assembly

The composite sandwich panel design addresses the weight and structural issues of existing panels by incorporating a core with non-developable wall geometry and a solid frame perimeter, achieved through a thermoforming process. This design results in a lightweight panel with enhanced structural integrity and efficient assembly, suitable for transportation applications.

WO2024254378A9 Publication Date: 2025-03-27MULTISCALE SYST INC
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Patent Information

Application Number
PCT/US2024/032911
Authority / Receiving Office
WO · WO
Patent Type
Applications
Current Assignee / Owner
Priority Date
2023-06-07
Filing Date
2024-06-07
Publication Date
2025-03-27

AI Technical Summary

Technical Problem

Existing composite sandwich panels are heavy due to their high density polyethylene foam cores and steel skins, which increases fuel consumption and costs in transportation applications. Alternative lightweight materials like polystyrene foam or polypropylene honeycomb suffer from structural drawbacks such as low shear strength and complex assembly requirements.

Method used

A composite sandwich panel design featuring a core with non-developable wall geometry, increased surface area for bonding, and a solid frame perimeter. This design is achieved through a thermoforming process that creates a trough in the perimeter, allowing for robust fastening using conventional and custom mechanical fastening methods, while reducing weight and enhancing structural integrity.

Benefits of technology

The proposed design results in a lightweight panel with high structural integrity, facilitating efficient assembly and reducing weight-related costs in transportation applications. The increased shear strength density and bonding surface area enhance the panel's performance and durability.

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Abstract

A core for a composite sandwich panel, a composite sandwich panel, and a method forming a composite sandwich panel, the composite sandwich panel including a core pic properties and to increase a shear strength density scaling, the core defining a generally planar element having a front side and an opposing rear side, a frame that outlines a perimeter of the core, shims received within the frame and configured to accommodate mechanical fasteners, and a skin composed of a thin material having a high tensile strength, a width sufficient to provide reinforcement for joinery, and where the core includes bonding surfaces that extend generally parallel to the skin and provide increased area contact for enhanced adhesion to the skin.
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