Composite Panel with Patterned Structural Foam Core
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Solution Overview
Problem
Existing structural panels for vehicles such as RVs, buses, and aircraft are costly, heavy, and require multiple assembly steps due to their multi-part construction, and are not inherently water or weather resistant, making them susceptible to deterioration from moisture and dirt.
Innovation Solution
A composite panel design featuring a lightweight internal preform surrounded by a cured composite matrix material, which creates a patterned structural portion with voids, and optionally includes reinforcing layers and a gel coat for enhanced strength and weather resistance, formed using a closed mold process to reduce weight and assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multi-part assemblies with welded tubes and multiple layers are used to provide structural strength, then strength is improved, but weight increases and device complexity increases
Solution Approach 1:
The patent uses a composite panel structure combining foam core material with fiber reinforcement layers (such as fiberglass or carbon fiber) to achieve high strength-to-weight ratio. The composite material provides both structural strength and weight reduction simultaneously, eliminating the need for heavy multi-part assemblies with welded tubes.
Solution Approach 2:
The patent implements local reinforcement by placing fiber reinforcement layers strategically at high-stress areas and critical load-bearing regions within the panel, rather than uniformly throughout the entire structure. This allows the panel to maintain strength where needed while minimizing weight in less critical areas.
2Strength
If multi-part assemblies with multiple components and fasteners are used to provide structural strength, then strength is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple structural components into a single integrated composite panel structure. The foam core, reinforcement layers, and structural elements are combined into one monolithic component that can be installed as a single unit, eliminating the need for multiple separate parts, fasteners, and complex assembly procedures.
Solution Approach 2:
The composite panel is pre-manufactured with all structural reinforcements and strength-enhancing features already integrated during manufacturing. This preliminary action eliminates the need for on-site assembly of multiple components, reducing both device complexity and installation time.
3Ease of manufacture
If traditional panel structures are used without inherent weather resistance, then manufacturing simplicity is maintained, but reliability deteriorates due to susceptibility to moisture and weathering
Solution Approach 1:
The composite panel uses inherently weather-resistant materials including foam core that resists moisture absorption and fiber reinforcement layers that provide durability against UV radiation, temperature extremes, and environmental degradation. This integration of weather resistance into the base materials eliminates the need for additional protective treatments while maintaining manufacturing simplicity.
4Strength
If solid composite material is used throughout the panel to maximize strength, then strength is improved, but weight increases
Solution Approach 1:
The patent applies fiber reinforcement layers selectively at high-stress areas, load-bearing regions, and critical structural zones within the panel, while leaving low-stress areas with lighter foam core material only. This localized application of heavy reinforcement material optimizes strength where needed while minimizing overall weight.
Solution Approach 2:
The panel is segmented into zones of different material density and reinforcement levels based on structural requirements. High-strength composite material is concentrated in critical areas, while less dense foam material is used in non-critical areas, creating a weight-optimized structure that maintains necessary strength.
Data Source
AI summary
A composite panel for use in applications such as mobile homes, boats, buses, RVs, or other panels used typically in transportation applications, where a single piece, water resistant, lightweight panel with patterned high-strength areas is needed. The composite panel generally includes internal preforms made of low-density material such as urethane foam, which create patterned structural portions of the panel during the molding process. The patterned structural portions are formed by a maze-like region within a mold, into which composite matrix material is infused. The patterned structural portions have high strength compared to the other regions of the panel, and can be used for structural support or for retaining fasteners for appliances, walls, etc.