Composite Panel Edge Reinforcement Without Inserts
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Solution Overview
Problem
There is a need for methods to reinforce and deform composite construction elements, such as sandwich panels, to create angled surfaces and edges without using inserts, while ensuring the reinforcement of angles and edges, and preventing material bulging during deformation.
Innovation Solution
A method involving a thermoplastic core layer with fiber-reinforced cover layers, where interruptions are made in the cover layers, and additional fiber-reinforced thermoplastic reinforcing layers are applied along the edges, which are then deformed using heat and pressure to form recesses delimited by fiber-reinforced walls, allowing for the creation of reinforced angles and edges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cover layer is interrupted and edges are deformed to form angles, then the panel can be reinforced without inserts, but material bulging occurs during deformation
Solution Approach 1:
A groove is created in the panel along the folding line before deformation. This preliminary action provides a defined path for the material to follow during deformation, preventing uncontrolled bulging while enabling insert-free reinforcement through edge deformation.
2Strength
If fiber-reinforced reinforcing layers are added along interruptions, then edge strength is improved, but panel complexity increases
Solution Approach 1:
The reinforcing layer is integrated directly into the panel structure during the deformation process. The fiber-reinforced thermoplastic layer is positioned in the groove and bonded to the panel edges, merging the reinforcement function with the structural panel rather than adding separate components.
Solution Approach 2:
The fiber-reinforced reinforcing layer is applied only along the interruption edges where strength is needed, rather than throughout the entire panel. This localized reinforcement provides necessary edge strength while minimizing overall structural complexity.
3Reliability
If edges are deformed to form recesses with fiber-reinforced walls, then impact resistance is improved, but manufacturing difficulty increases
Solution Approach 1:
The groove is formed in advance along the folding line before the actual edge deformation. This preliminary groove creation simplifies the subsequent deformation process by providing a predetermined path, reducing the complexity of forming impact-resistant recesses with fiber-reinforced walls.
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 method enables the production of lightweight, strong composite panels with reduced height, suitable for aerospace applications, and allows for the integration of supporting structures within the panel design, reducing weight and increasing space, while providing impact-resistant connections without the need for additional inserts.
Implementation Method 1
softening a part of one of the surfaces of the thermoplastic sandwich material with the aid of a stamp
Implementation Method 2
the excess material of the softened top layer of the sandwich material is present on the inside of the angle, and is melted in the foam core in the folded state
Data Source
Figure 1~7
Figure 8~11
Figure 12~13
AI summary
A method for producing a composite construction element (10) comprises the steps of : a) providing a composite construction element (10), which comprises a thermoplastic core layer (12) between two fiber-reinforced thermoplastic cover layers (14, 16); b) providing one or more interruptions (50) in a fiber-reinforced thermoplastic cover layer (14) of the panel (10); c) positioning a fiber-reinforced thermoplastic reinforcing layer (70) over and/or near the interruption (50); d) deforming situated along the interruption (50) and, if desired, the thermoplastic reinforcing layer (70), preferably while simultaneously locally compacting the core layer (12), so that a thermoplastic construction element having a recess which is delimited by fiber-reinforced thermoplastic walls is obtained.