Composite Panel Attachment Profile Corrosion Protection
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Solution Overview
Problem
Steel composite panels used in building façades and constructions are prone to crevice corrosion, especially in weathering steels like COR-TEN, which are sensitive to galvanic contacts at seams and joints, leading to premature degradation.
Innovation Solution
A sandwich-structured composite panel design featuring sheet metal face skins with a thermally insulating core and a hydrophobic protective layer on the attachment profile to inhibit galvanic contacts, combined with a tongue-and-groove attachment system, reduces crevice corrosion at panel joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If weathering steel is used to eliminate painting and achieve stable rust-like appearance, then aesthetic appearance and durability are improved, but sensitivity to crevice corrosion at joints increases
Solution Approach 1:
The patent applies different surface treatments to different parts of the panel: the face skins maintain the weathering steel's natural rust-like appearance without protective coating, while the attachment profiles receive a protective layer (paint, polymer, or other coating) to prevent crevice corrosion. This local differentiation allows the panel to enjoy both the aesthetic benefits of weathering steel and the corrosion protection needed at vulnerable joint areas.
2Object-affected harmful factors
If protective layer is applied to entire panel surface, then crevice corrosion resistance is improved, but aesthetic appearance and breathability of weathering steel are compromised
Solution Approach 1:
The protective layer is selectively applied only to the attachment profiles where crevice corrosion occurs, while the face skins remain exposed to develop their characteristic rust-like appearance. This localized approach preserves the aesthetic qualities of weathering steel while providing corrosion protection exactly where needed.
3Strength
If attachment profiles are formed from sheet metal for tongue-and-groove attachment, then structural strength and panel stability are improved, but galvanic contacts at joints increase crevice corrosion risk
Solution Approach 1:
The patent introduces a protective layer as an intermediary substance between the metal attachment profiles. This layer acts as a barrier that prevents direct galvanic contact between dissimilar metals at the joints, thereby eliminating the electrochemical reactions that cause crevice corrosion while maintaining the structural integrity of the tongue-and-groove attachment system.
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 solution effectively prevents galvanic contacts and enhances resistance to crevice corrosion at composite panel attachment joints, extending the lifespan of the panels and reducing maintenance needs.
Implementation Method 1
a protective layer of hydrophobic material arranged on the outer surface of a portion of the sheet metal in the attachment profile, for inhibiting or attenuating galvanic contacts or couplings between composite panels attached to each other
Data Source
Figure 1
Figure 2a~2d
AI summary
A sandwich-structured composite panel (1), and a method for manufacturing the composite panel. The composite panel (1) comprises a first face skin (3) of sheet metal, a second face skin (4) of sheet metal, and a core (5) made of thermally insulating material arranged between the first face skin and the second face skin, the first and second face skins being attached to the core. The composite panel (1) further comprises an attachment edge (2) at the edge of the composite panel (1) for attaching the composite panel to another composite panel (1). The attachment edge (2) comprises an attachment profile (6) being formed from the sheet metal of at least one of said skins (3, 4) and shaped for a tongue- and-groove attachment. The sandwich-structured composite panel (1) further comprises a protective layer (7) of hydrophobic material arranged on the outer surface of a portion of the sheet metal in the attachment profile (6).