Composite Sandwich Panel Assembly with Integrated Clamping
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Solution Overview
Problem
Existing methods for assembling sandwich composite panels in vehicle bodywork and chassis structures are costly and restrictive due to the need for fixed jigs and external clamping systems, and they fail to provide a solid anchoring solution for attaching equipment, leading to stress concentration and reduced lifespan of the composite material.
Innovation Solution
A self-supporting structure is formed by assembling panels with complementary profiles and clamping means that occupy an active state to create a three-dimensional shape, using clamping members, spacer wedges, and adhesive to secure the panels, allowing for the integration of mounting members with inclined bases to distribute forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed jigs and external clamping systems are used to assemble sandwich composite panels, then assembly stability and positioning precision are improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the positioning, clamping, and support functions into the panel profiles themselves. The complementary profiles include integrated clamping means (such as recesses, protrusions, or interlocking features) that directly engage with corresponding features on adjacent panels, eliminating the need for separate external clamping systems and fixed jigs.
Solution Approach 2:
The panel profiles are designed to be self-positioning and self-clamping. When panels are brought together, their complementary profiles automatically align and engage, with the clamping means occupying an active state to maintain the three-dimensional shape and structural integrity without requiring external intervention or additional devices.
2Ease of manufacture
If inserts are fixed to sandwich structure panels through single skin attachment, then installation simplicity is improved, but anchoring strength and reliability deteriorate
Solution Approach 1:
The patent transitions from single-skin attachment to multi-skin attachment by extending the insert through the entire thickness of the sandwich structure, engaging both outer skins and the core. This three-dimensional anchoring approach distributes loads across multiple layers, significantly improving reliability while maintaining manufacturing feasibility.
Solution Approach 2:
The insert design leverages the composite nature of the sandwich structure by integrating with both the rigid outer skins and the compliant core material. This allows the insert to benefit from the high strength of the skins and the energy-absorbing characteristics of the core, achieving superior anchoring performance.
3Reliability
If inserts protrude from both sides of the panel for dual skin fixation, then anchoring strength is improved, but safety and comfort deteriorate due to injury risk
Solution Approach 1:
The patent extracts the protruding insert ends from the panel assembly by designing the insert to terminate within the panel thickness or to be flush with the outer skin surfaces. This eliminates the hazardous protruding elements while preserving the dual-skin anchoring mechanism that provides superior strength.
Solution Approach 2:
Instead of having inserts protrude outward from both sides, the patent inverts the design so that the insert is contained within the panel boundaries, with the anchoring mechanism operating internally through the core and skins without creating external hazards.
4Ease of manufacture
If forces are localized inside the composite material for element fixation, then attachment simplicity is improved, but material stress and lifespan worsen
Solution Approach 1:
The patent segments the force transmission path by distributing the attachment forces across multiple discrete locations within the sandwich structure. Instead of concentrating loads at single points, the design uses multiple inserts or distributed anchoring features that spread the stress across different regions of the core and skins, reducing localized stress concentration.
Solution Approach 2:
The patent applies local quality enhancement by reinforcing the regions around insert locations with additional material or structural features. This could include localized thickening of the core, addition of reinforcement ribs, or modification of the skin geometry around attachment points, thereby strengthening specific areas without compromising the overall simplicity of the attachment system.
Data Source
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AI summary
The invention relates to a self-supporting structure formed by assembling at least two composite material sandwich structure panels. Said two panels have, respectively, two assembly portions having complementary profile elements (31, 32) that each have at least one means for clamping the panels that is located along the complementary profile elements. Said clamping means (35, 36) can occupy an active state for maximum clamping of the two panels. The assembly portions are profiled such that, when the clamping means occupy the active state, the two interlocking panels have a three-dimensional shape corresponding to that of said two panels in the structure to be created and form a self-supporting substructure. The invention also relates to the method for assembling said structure, to the panel from which the assembly is created, and to a motor vehicle, the body and/or chassis of which is formed from an assembly of said panels.