Composite Panel Differential Resin Layers
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Solution Overview
Problem
Existing composite sandwich panels with honeycomb cores face challenges in weight optimization due to even resin distribution and the need for additional adhesive layers, which increase manufacturing costs and weight, particularly in aerospace applications where high strength and low weight are critical.
Innovation Solution
A composite panel design featuring unidirectional prepreg skins with selectively applied resin on contact surfaces, allowing for differential resin distribution to eliminate the need for a separate adhesive film, thereby reducing weight and manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If an evenly distributed resin layer is applied across the honeycomb core with an auxiliary film adhesive, then the bonding strength between face sheets and core is ensured, but the panel weight increases and manufacturing complexity increases
Solution Approach 1:
The patent applies resin selectively only at the contact surfaces between the honeycomb core and face sheets, rather than distributing resin evenly across the entire core. This localized resin application provides sufficient bonding strength at the critical interface while eliminating unnecessary resin weight in non-contact areas, directly resolving the contradiction between bonding strength and panel weight.
Solution Approach 2:
The patent eliminates the auxiliary film adhesive layer entirely by using differential resin application through the prepreg. By extracting the separate adhesive film and replacing it with strategically placed resin within the prepreg structure, the patent reduces panel weight and manufacturing complexity while maintaining the necessary bonding strength through the cured resin at contact surfaces.
2Reliability
If an auxiliary film adhesive is added to bond face sheets to honeycomb, then bonding reliability is improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent merges the adhesive function into the prepreg structure itself by applying differential resin layers. Instead of using a separate auxiliary film adhesive, the resin within the prepreg is strategically positioned to provide bonding at the honeycomb contact surfaces. This integration eliminates the need for separate adhesive application steps and reduces manufacturing complexity while maintaining bonding reliability.
Solution Approach 2:
The patent extracts and eliminates the auxiliary film adhesive component from the bonding system. By relying solely on the differentially applied resin within the prepreg to provide bonding at critical interfaces, the patent simplifies the overall structure and manufacturing process while maintaining sufficient bonding reliability for the application.
3Area of stationary object
If resin is applied evenly across the entire honeycomb core, then complete coverage is achieved, but resin weight and material cost increase unnecessarily
Solution Approach 1:
The patent applies resin selectively only where needed - at the contact surfaces between the honeycomb core and face sheets - rather than distributing resin evenly across the entire core surface. This localized application achieves complete coverage at the critical bonding interfaces while minimizing the total quantity of resin used, directly resolving the contradiction between coverage area and resin quantity.
Solution Approach 2:
The patent uses partial action by applying resin only to the necessary contact areas rather than providing excessive coverage across the entire core. By limiting resin application to the specific regions where bonding is required, the patent achieves sufficient coverage for structural integrity while significantly reducing the total resin quantity and associated weight and cost.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a lightweight, high-strength panel with reduced resin content and manufacturing costs, enhancing weight characteristics and efficiency while maintaining structural integrity.
Implementation Method 1
The resin system is typically an epoxy that already includes the proper curing agent. These pre-impregnated composite fabrics and tapes, or 'prepregs,' are used in a large number of aircraft applications. A film adhesive is typically added to the prepreg honeycomb core and it is then bonded to the honeycomb by curing of both the prepreg resin and adhesive resin at an elevated temperature.
Data Source
AI summary
A composite panel includes a honeycomb core sandwiched by a pair of skins that are attached directly to the core with no separate adhesive layer. The skins are impregnated with a resin material that is unevenly distributed between first and second surfaces, and direct contact is established between the surfaces with the greater resin distribution and the core, reducing weight and eliminating the manufacturing step of incorporating an adhesive layer therebetween.