Composite Panel Assembly With Reinforced Flanges for Shock Resistance
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Solution Overview
Problem
Composite panel assemblies in vehicles and furniture lack mechanical resistance and durability, especially when subjected to mechanical stress and shocks, and fail to meet design requirements for aesthetic and functional needs.
Innovation Solution
A composite panel assembly design featuring reinforcing pins in the core material, angled assembly flanges, and a core with varying densities to enhance mechanical resistance and load transmission, along with a cover element for impact absorption, allowing for a lightweight yet robust structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If composite panels are assembled together at corners or angles, then complex forms can be created, but the transmission of loads becomes complex and mechanical resistance decreases
Solution Approach 1:
The panel assembly is divided into modular units with standardized connection elements. Each panel includes integrated connection features that segment the load transmission paths, allowing complex geometric arrangements while maintaining structural integrity through discrete, optimized connection points rather than continuous complex joints.
Solution Approach 2:
The invention employs composite panel construction with optimized material properties at connection zones. The panels use composite structures that enhance mechanical resistance at joints through material layering and configuration, allowing complex shapes to be assembled while maintaining strength through the inherent properties of composite materials at critical connection points.
2Weight of moving object
If lightweight core materials are used in composite panels, then weight is reduced, but mechanical resistance under stress and shocks decreases
Solution Approach 1:
The core material density is varied locally within the panel structure. Lightweight core materials are used in non-critical areas to reduce overall weight, while reinforced core sections with higher density or additional structural features are positioned at connection zones and high-stress areas to maintain mechanical resistance and durability under stress and shocks.
Solution Approach 2:
The panel uses composite construction combining lightweight core materials with reinforcing elements. The composite structure integrates lightweight materials for weight reduction while incorporating stronger materials or structural configurations at critical locations to ensure reliability and durability under mechanical stress and shock conditions.
3Strength
If panel thickness is increased to improve mechanical resistance, then strength increases, but weight increases
Solution Approach 1:
Panel thickness is optimized locally rather than uniformly. Thinner sections are used in low-stress areas to reduce weight, while increased thickness or additional reinforcement is applied only at connection zones and high-stress areas to maintain mechanical resistance, achieving strength enhancement without proportional weight increase.
Solution Approach 2:
The panel employs composite material construction that provides high mechanical resistance with reduced weight. The composite structure uses multiple material layers with different properties, allowing thin overall thickness while maintaining strength through the synergistic combination of materials and their strategic arrangement.
4Ease of manufacture
If standardized connection methods are used for composite panels, then manufacturing is simplified, but design requirements for furniture are not met
Solution Approach 1:
The connection system is designed with universal features that can accommodate multiple design configurations. The standardized connection elements include adjustable and configurable features that maintain manufacturing simplicity while adapting to various furniture design requirements, allowing the same basic connection mechanism to serve multiple aesthetic and functional purposes.
Solution Approach 2:
The connection system incorporates dynamic or adjustable elements that allow modification after manufacturing. This enables standardized components to be adapted to different design requirements through reconfiguration, providing versatility for furniture applications without compromising the simplicity of the initial manufacturing process.
Data Source
AI summary
A composite panel assembly including a first panel with a first skin, a second skin, a core, and an assembly flange. A second panel includes a first skin, a second skin, a core, and an assembly flange. A fastening device is adapted to fasten the assembly flange of the first panel to the assembly flange of the second panel, wherein the core of one of the first panel or the second panel includes reinforcing pins and a high-density portion placed along the assembly flange.