Composite Panel with Foam Core and Bio-Resin Binding
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Solution Overview
Problem
Air conditioning units for commercial and industrial applications are predominantly made of metallic materials, which do not effectively address mechanical and thermal constraints, and there is a need for composite panels that can withstand temperature variations and mechanical loads while being lighter and fire-resistant.
Innovation Solution
A composite panel comprising a foam core bonded between two composite skins made of glass fibers and Kraft paper layers, with a bio resin binding composition that penetrates the layers to form a hardened surface, allowing the panel to withstand temperature deltas and mechanical loads while providing fire protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic materials are used for air conditioning unit casings, then mechanical strength and fire resistance are improved, but weight increases and thermal insulation performance deteriorates
Solution Approach 1:
The patent employs a composite panel structure consisting of a foam core (providing thermal insulation and fire resistance) bonded to two composite skins made of glass fiber fabric layers impregnated with bio-resin (providing mechanical strength). This composite construction achieves the required mechanical properties while significantly reducing weight compared to solid metallic casings.
2Strength
If metallic materials are used for air conditioning unit casings, then mechanical strength is improved, but thermal insulation performance deteriorates
Solution Approach 1:
The composite panel uses a foam core material that provides excellent thermal insulation properties, creating a thermal barrier between the interior and exterior environments. The composite skins provide structural strength while the foam core handles thermal insulation, resolving the contradiction between mechanical strength and thermal performance.
3Strength
If composite panels with multiple layers are manufactured, then mechanical strength and fire resistance are improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs pre-impregnated (prepreg) fabric layers where the glass fiber fabric is预先 impregnated with bio-resin before assembly. This preliminary impregnation simplifies the manufacturing process by eliminating the need for separate resin application and distribution steps, reducing manufacturing complexity while maintaining the required multi-layer composite structure for strength and fire resistance.
4Object-affected harmful factors
If bio-resin is used as binding composition, then fire resistance is improved, but manufacturing precision requirements increase
Solution Approach 1:
By pre-impregnating the fabric layers with bio-resin before assembly, the resin distribution is controlled during the impregnation process rather than during final panel manufacturing. This preliminary action ensures uniform resin distribution and reduces the precision requirements for the bonding process, while still achieving the fire resistance benefits of bio-resin.
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 composite panel effectively withstands temperature variations between the inside and outside environments of air conditioning units without compromising mechanical properties, carries significant mechanical loads, and meets fire protection regulations, offering a lighter alternative to conventional metallic materials.
Implementation Method 1
a binding composition applied to the first fabric layer and to the second fabric layer and penetrating the second Kraft paper layer and the third Kraft paper layer so that the first composite skin is bonded to a first surface of the foam core
Implementation Method 2
penetrating the second Kraft paper layer and the third Kraft paper layer
Implementation Method 3
the panels are designed so as to withstand important thermic variations without bonding and/or impairing mechanical properties of the casing
Data Source
AI summary
A composite panel comprising a first composite skin having a first fabric layer positioned between a first Kraft paper layer and a second Kraft paper layer; a second composite skin having a second fabric layer positioned between a third Kraft paper layer and a fourth Kraft paper layer; a foam core bonded to the first composite skin and to the second composite skin; and a binding composition applied to the first fabric layer and to the second fabric layer and penetrating the second Kraft paper layer and the third Kraft paper layer so that the first composite skin is bonded to a first surface of the foam core and the second composite skin is bonded to a second surface of the foam core.