Composite Panel Joint Construction Without Filler Layer
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Solution Overview
Problem
Existing composite panel joint constructions are costly and impair the structural integrity of composite panels due to filler layer impairment, particularly in applications like truck trailers and cargo containers where buckling is a concern.
Innovation Solution
A composite panel joint construction with a filler layer absent in the joint region, where the panel faces are directly adjacent or joined with an adhesive, maintaining structural integrity by eliminating the filler layer in the joint section and using joining members like posts and connectors to secure adjacent panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connectors are used to join composite panels, then the panels can be linked together, but the filler layer is impaired and structural integrity is reduced
Solution Approach 1:
The invention extracts the filler layer from the joint region, creating a filler-free zone where panels are joined directly face-to-face. This eliminates the interference of the filler layer with connectors and allows direct structural connection between panels, resolving the contradiction between ease of manufacture and structural integrity.
Solution Approach 2:
The panel is segmented into a joint region and non-joint regions. The joint region is specifically designed without filler layer to accommodate connectors and provide structural connection, while other regions maintain the sandwich construction with filler layer for insulation and structural purposes.
2Ease of manufacture
If connectors are used to join composite panels, then panels can be linked together, but the cost increases
Solution Approach 1:
By removing the filler layer from the joint region, the invention eliminates the need for expensive connectors and filler material in that area. The direct face-to-face joining reduces material consumption and manufacturing cost while maintaining joining capability.
Solution Approach 2:
The invention discards the filler layer in the joint region where it is not needed for structural connection. This selective removal reduces material usage and cost in the specific area where joining occurs, while preserving the filler layer in regions where it provides functional value.
3Length of stationary object
If multiple composite panels are joined in series to form elongated walls, then longer constructions are achieved, but buckling risk increases
Solution Approach 1:
The wall construction is segmented into multiple panels with dedicated joint regions. Each joint region is designed with direct face-to-face connection and reinforcing members to provide localized structural support, allowing the overall wall to achieve greater length while maintaining buckling resistance through distributed reinforcement points.
Solution Approach 2:
The joint region uses a composite construction combining the panel faces directly connected with additional reinforcing members. This composite structure in the joint region provides enhanced local stiffness and buckling resistance, enabling longer wall constructions while maintaining reliability.
Data Source
AI summary
A composite panel comprises a first outer layer, a second outer layer, a filler layer, and a joint section of the composite panel. The filler layer is positioned between a portion of the respective first and second outer layers. The first and second outer layers are positioned adjacent one another without an intervening filler layer.