Composite Panel Aesthetic Edge Design via Shell Layer Coupling

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Solution Overview

Problem

Composite articles often have unsightly edges due to the processes and materials used in their preparation, which can detract from their aesthetic appeal in various applications.

Innovation Solution

A composite panel design featuring a sandwich panel with a shell layer coupled to provide an aesthetic edge, comprising a first skin and a second skin with reinforcing fibers and a core layer, where the shell layer and sandwich panel together create a directional change in the edge, potentially with an air gap for added visual appeal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If traditional composite article preparation processes are used, then manufacturing efficiency is maintained, but the edges become unsightly and aesthetically unappealing

Engineering Contradiction:

Improveedge appearanceVSAvoidmanufacturing process complexity

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The composite article is divided into separate components: a core composite structure and a distinct edge band layer. This segmentation allows each component to be manufactured independently using optimized processes, then assembled together to achieve both aesthetic edges and manufacturing efficiency.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The edge band layer is pre-formed with the desired aesthetic appearance and properties before being applied to the composite article. This preliminary preparation of the edge component allows for controlled manufacturing of the aesthetic feature without disrupting the main composite production process.

Inventive Principle:

Principle #10Preliminary action

2Shape

If edge treatment processes are added to improve appearance, then aesthetic appeal increases, but manufacturing time and complexity increase

Engineering Contradiction:

Improveedge aesthetic qualityVSAvoidmanufacturing cycle time

Core Design Contradiction:

ShapeVSLoss of time

Solution Approach 1:

The edge band layer is combined with the core composite structure in a single assembly operation. This merging of the aesthetic edge component with the structural core eliminates the need for separate edge treatment processes, achieving both improved appearance and maintained manufacturing speed.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The solution uses a composite structure where an edge band layer (which can be a different material optimized for aesthetics) is combined with the core composite material. This allows each layer to be optimized for its specific function: structural integrity and visual appeal, respectively.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11628646B2Composite panels including an aesthetic edge

Publication Date: 2023.04.18 AZDEL INC

AI summary

Certain configurations of composite panels are described that comprise at least one aesthetic edge. In some embodiments, the composite panel with the aesthetic edge comprises a sandwich panel coupled to a shell layer. The sandwich panel may comprise skin layers and a core layer.