Composite Sandwich Panel Monolithic Extension

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Solution Overview

Problem

Existing metal structures in transportation are heavy and costly to maintain, while their replacement with composite sandwich structures offers weight reduction but requires additional functions and complex manufacturing processes to integrate equipment effectively.

Innovation Solution

The development of a composite sandwich panel structure with a monolithic extension that forms a single wall, allowing for reduced thickness and additional functions such as conduit formation, by extending one or both skins beyond the panel edge and securing them to create a support or attachment edge, which can also serve as a base for integrated equipment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If metal structures are replaced with composite sandwich structures, then weight is reduced, but additional functions and complex manufacturing processes are required to integrate equipment effectively

Engineering Contradiction:

ImproveweightVSAvoidmanufacturing process complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The patent merges the structural panel and equipment housing into a single integrated component. The sandwich panel includes an integrated cavity that directly houses equipment such as air conditioning units, eliminating the need for separate mounting structures and reducing manufacturing steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sandwich panel serves multiple functions simultaneously: it provides structural support, thermal insulation, acoustic insulation, and equipment housing. This multi-functionality reduces the number of separate components needed and simplifies the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Adaptability or versatility

If equipment is integrated into composite sandwich structures, then additional functions are achieved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improveadditional functionsVSAvoidmanufacturing process

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The equipment cavity is formed as an integral part of the sandwich panel during the panel's initial manufacturing process. Core materials are positioned and shaped beforehand to create the necessary cavities, allowing equipment to be installed directly into the pre-formed spaces without additional manufacturing steps.

Inventive Principle:

Principle #10Preliminary action

3Weight of moving object

If the panel thickness is reduced in extended areas, then weight is reduced, but structural strength may be compromised

Engineering Contradiction:

ImproveweightVSAvoidstructural strength

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The sandwich panel features variable thickness with different core densities in different regions. Areas requiring higher strength retain full thickness with dense core material, while non-critical areas use reduced thickness with lighter core material, optimizing the strength-to-weight ratio throughout the structure.

Inventive Principle:

Principle #3Local quality

Data Source

PatentEP3297820B1Sandwich structure having an extension forming an additional structure

Publication Date: 2021.04.28 ARIANEGRP SAS

Figure 1
Figure 2~4
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AI summary

The invention relates to a composite structure comprising a composite sandwich panel (1) consisting of a first skin (10) and a second skin (11) on either side of a core (12), comprising at least one extension of an edge of the composite sandwich panel produced by a one-piece portion forming a single wall extending the composite sandwich panel beyond an attachment edge of the panel, said single wall forming an additional panel having a smaller thickness than the composite sandwich panel (1).