Lightweight Composite Panel with Fiber-Reinforced Skins
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Solution Overview
Problem
Composite panels with foamed materials of low density suffer from reduced strength and susceptibility to buckling under concentrated loads, and existing solutions do not effectively combine sound absorption and fire properties with structural integrity.
Innovation Solution
A composite panel design featuring a layer of foamed material with a density of less than 100 kg/m3 sandwiched between two layers of fiber-reinforced polyisocyanurate material, where the foamed layer is thicker than the polyisocyanurate layers, using a reactive binder composition of polyisocyanate, polyol, and trimerization catalyst, and incorporating specific fiber types and foam properties for enhanced strength and sound absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the density of the rigid foam is reduced to achieve lightweight panels, then the weight is reduced, but the flexural strength and flexural modulus are reduced and buckling occurs under concentrated loads
Solution Approach 1:
The patent applies composite materials by combining a low-density foamed material layer with fiber-reinforced plastic layers. The foam core provides lightweight properties while the fiber-reinforced skins provide structural strength, creating a composite sandwich structure that achieves both low weight and high flexural strength. This resolves the contradiction by distributing functions across different materials in the composite system.
Solution Approach 2:
The patent applies local quality by having different regions of the panel with different properties: the core foam layer has low density for weight reduction, while the outer fiber-reinforced layers have high strength for structural integrity. Each layer is optimized for its specific function, allowing the overall panel to achieve both lightweight and high-strength characteristics simultaneously.
2Weight of moving object
If the density of the rigid foam is reduced to achieve lightweight panels, then the weight is reduced, but buckling occurs in the foam layer under concentrated loads
Solution Approach 1:
The composite sandwich structure with fiber-reinforced plastic skins bonded to the foam core prevents buckling by providing a rigid framework that constrains the foam layer. The fiber-reinforced layers act as protective shells that distribute concentrated loads and prevent local instability in the low-density foam core, maintaining reliability while keeping weight low.
Solution Approach 2:
The fiber-reinforced plastic layers serve as a protective framework that is applied beforehand to the foam core. This reinforcement layer acts as a preventive measure against buckling under concentrated loads, providing structural support and distributing stresses before they can cause instability in the foam layer.
3Object-affected harmful factors
If a multilayered product with variation in rigidity is created using spongy polymer and polyurethane resin, then sound absorption is improved, but the layer structure becomes complicated
Solution Approach 1:
The patent applies local quality by having the foamed material layer provide sound absorption in specific regions where acoustic performance is needed, while the fiber-reinforced plastic layers provide structural functions. This localized functional differentiation achieves sound absorption without requiring complex multilayered constructions, simplifying the overall layer structure while maintaining acoustic performance.
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
The design achieves a lightweight panel with high strength and excellent fire properties, suitable for sound absorption and insulation applications, maintaining structural integrity while minimizing buckling risks.
Implementation Method 1
a composition comprising a polyisocyanate and a polyol to react at elevated temperature in a mould and in the presence of a trimerization catalyst
Implementation Method 2
react at elevated temperature in a mould and in the presence of a trimerization catalyst
Data Source
AI summary
Composite panel which comprises a layer of foamed material having a density of less than 100 kg/m3 which layer is sandwiched between 2 layers of fiber reinforced polyisocyanurate material.