Composite panel, composite material, impregnator and method for manufacturing a composite panel
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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 with glass fibers and Kraft paper layers, using a bio resin binding composition that penetrates the Kraft paper layers to form hardened surfaces, allowing the panel to withstand temperature deltas and mechanical loads while being non-flammable.
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 applies composite materials by combining glass fiber fabric layers with bio-resin binding composition to create a panel structure that achieves both mechanical strength and weight reduction. The composite construction allows the panel to meet mechanical load requirements while being significantly lighter than traditional metallic materials.
2Stability of the object's composition
If metallic materials are used for air conditioning unit casings, then structural rigidity is improved, but thermal insulation performance and fire resistance deteriorate
Solution Approach 1:
The composite panel structure with glass fiber and bio-resin provides both structural rigidity and thermal insulation properties. The bio-resin binding composition contributes to fire resistance while maintaining the panel's mechanical stability under temperature variations.
Solution Approach 2:
The patent utilizes the temperature-resistant properties of glass fiber and bio-resin to maintain structural integrity under thermal stress. The material composition is selected to withstand temperature deltas up to 40°C between inside and outside environments without compromising mechanical properties.
3Weight of moving object
If composite materials are used instead of metallic materials, then weight is reduced and fire resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The glass fiber fabric layers are pre-impregnated with bio-resin binding composition before assembly, which simplifies the manufacturing process by reducing on-site processing requirements. This preliminary impregnation ensures proper resin distribution and reduces manufacturing complexity.
Solution Approach 2:
The patent combines multiple functions into a single composite panel structure that simultaneously provides mechanical strength, thermal insulation, and fire resistance. The integration of glass fiber and bio-resin in a layered configuration achieves multiple performance requirements without requiring separate components.
4Stability of the object's composition
If composite panels are designed to withstand temperature variations, then thermal stability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent selects materials with appropriate thermal expansion coefficients and glass transition temperatures to ensure the composite panel can withstand temperature deltas of up to 40°C. The bio-resin binding composition is specifically chosen for its thermal stability characteristics.
Solution Approach 2:
The panel is constructed with multiple discrete layers of glass fiber fabric and bio-resin that can accommodate thermal expansion and contraction independently. This segmented layered structure reduces internal stresses during temperature cycling while maintaining overall panel integrity.
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 provides fire protection, making it suitable for air conditioning unit casings.
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 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
Implementation Method 4
the panels are designed so as to withstand important thermic variations without bonding and/or impairing mechanical properties of the casing
Implementation Method 5
a first composite skin having a first fabric layer positioned between a first Kraft paper layer and a second Kraft paper layer
Data Source
AI summary
An impregnator for impregnating a fabric layer comprising: a chamber, the chamber being structured and arranged so as to retain a binding composition in a fluid state; a first opening being structured and arranged so as to allow the fabric layer entering the chamber in a dry state from a top portion of the chamber to be dived into the binding composition; and a second opening extending along the longitudinal axis of a bottom portion of the chamber, the second opening being structured and arranged to allow the fabric layer to exit from the bottom portion of the chamber in an impregnated state, the second opening comprising a first lip structured and arranged to be in contact with a first surface of the fabric layer and a second lip structured and arranged to be in contact with a second surface of the fabric layer.