Sandwich Composite Panel Living Hinge Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing sandwich-type composite panels with living hinges require additional processing steps and materials, leading to increased manufacturing time and cost, as well as potential quality defects due to separate hinge components.
Innovation Solution
A method involving a stack of reinforced thermoplastic skins, thermoplastic adhesive sheets, and a cellulose-based cellular core, where the skins are heated and pressed to form a composite panel with a living hinge by crushing a portion to locally compact the core, creating a strong and integrated hinge without additional post-processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate hinges are fixed to sandwich-structure composite panels in a subsequent operation, then the panels can achieve hinged functionality, but the manufacturing time and manufacturing cost increase
Solution Approach 1:
The hinge functionality is merged into the panel structure itself by creating a living hinge as an integral part of the sandwich composite panel during the same manufacturing process, eliminating the need for separate hinge components and subsequent assembly operations
Solution Approach 2:
The hinge structure is pre-formed during the panel manufacturing process itself, with the living hinge being created as the panel is being molded, rather than adding hinges in a subsequent separate operation
2Adaptability or versatility
If separate hinges are fixed to sandwich-structure composite panels, then the panels can achieve hinged functionality, but the manufacturing cost increases
Solution Approach 1:
The hinge functionality is merged into the panel structure itself by creating a living hinge as an integral part of the sandwich composite panel during the same manufacturing process, eliminating the need for separate hinge components and subsequent assembly operations
Solution Approach 2:
The single manufacturing process simultaneously produces both the panel structure and the hinge functionality, making the manufacturing process multi-functional and eliminating the need for separate hinge components and assembly operations
3Adaptability or versatility
If separate external parts are mounted on composite panels, then the panels can achieve additional functionality, but quality defects increase
Solution Approach 1:
The hinge functionality is merged into the panel structure itself by creating a living hinge as an integral part of the sandwich composite panel during the same manufacturing process, eliminating the need for separate hinge components and subsequent assembly operations
Solution Approach 2:
The living hinge is made from the same material as the panel itself, creating a homogeneous structure without interfaces between different materials or components, thereby eliminating quality defects associated with separate parts and assembly
4Stability of the object's composition
If a living hinge is formed by crushing a portion of the panel, then the hinge is integrated into the panel structure, but the cellular core is locally compacted
Solution Approach 1:
The crushing process creates a localized region with different properties (the living hinge) while leaving the rest of the panel structure intact, with the cellular core being compacted only in the specific area where the hinge is needed
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 sandwich-type composite panels with integrated living hinges, reducing manufacturing time and costs while minimizing quality defects, as the hinges are formed in a single operation within the mold.
Implementation Method 1
a first sheet of thermoplastic adhesive and a second sheet of thermoplastic adhesive... wherein the skins are bonded to the core by the sheets
Implementation Method 2
heating the skins to a softening temperature wherein the first skin is stretchable when heated to the softening temperature
Implementation Method 3
applying a pressure to the stack after the step of heating wherein the skins are bonded to the core by the sheets
Implementation Method 4
crushing a portion of the composite panel at a predetermined location simultaneously with the step of applying to locally compact and separate the cellular core
Data Source
AI summary
A method of making a sandwich-type composite panel having a cellulose-based core and a living hinge from a stack of material is provided. The stack includes first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based cellular core disposed between the sheets and the skins. A pressure is applied to the stack after heating the stack wherein the skins are bonded to the core by the sheets to form the composite panel. A portion of the composite panel is crushed at a predetermined location simultaneously with applying the pressure to locally compact and separate the cellular core at the predetermined location to form two side portions of the panel. The heated first skin stretches during the step of crushing while remaining intact between the two side portions. The skins bond together at the predetermined location to form the living hinge.