Edge Insert Joining for Lightweight Sandwich Panel Reinforcement
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Solution Overview
Problem
Panel materials with discontinuous density profiles, particularly lightweight sandwich panels, face challenges in machine processing due to reduced compressive strength and transverse tensile strength, leading to issues with assembly, connection, and functional integration, such as inadequate fastening and limited use of conventional connection technologies.
Innovation Solution
An insert system comprising an insert and a complementary recess in panel-shaped components with a discontinuous density profile, where the insert is machined to fit precisely into the recess, allowing for enhanced bonding and integration of functional elements, enabling zonal functionalization and improved mechanical reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If lightweight sandwich panels with discontinuous density profiles are used, then weight is reduced and material savings are achieved, but compressive strength and transverse tensile strength are reduced, leading to processing and assembly difficulties
Solution Approach 1:
The panel is segmented into distinct density zones (edge area with higher density and core area with lower density), allowing each zone to serve different functional purposes while maintaining overall lightweight structure
Solution Approach 2:
Different regions of the panel are given different material densities tailored to local requirements: denser edge areas for strength and connection, lighter core areas for weight reduction, creating a non-uniform density distribution optimized for both weight and strength
2Ease of manufacture
If conventional connection technologies are used on lightweight panels, then assembly is simplified, but connection stability is significantly limited due to reduced material density and hollow structures
Solution Approach 1:
The edge area of the panel is designed with higher material density specifically at connection locations, creating localized reinforcement zones that provide adequate anchoring for conventional connection technologies while maintaining lightweight overall structure
Solution Approach 2:
The panel structure is pre-designed with reinforced edge areas and specific geometric features at connection points before assembly, ensuring that conventional connection technologies can be effectively applied without requiring modifications to the connection methods themselves
3Reliability
If frame wood is integrated into sandwich panels to improve connection stability, then assembly and connection technology is enhanced, but manufacturing complexity and production costs increase
Solution Approach 1:
The reinforcing function previously requiring separate frame wood elements is merged directly into the panel manufacturing process, creating an integrated structure where reinforcement and panel formation occur simultaneously, eliminating the need for separate frame installation steps
Data Source
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AI summary
The invention relates to a method for inserting an insert (1) and an insert system for the zonal functionalization of a plate-shaped component (2) in the edge region of a sheet material with a discontinuous density profile in the sheet cross-section, as well as of a multi-layer sandwich panel material. To functionalize the edge regions of a sheet with a discontinuous density profile, in particular a lightweight sandwich panel, at specific points and/or regionally, an insert system is provided which includes, in particular, materially bonded inserts (1) that are suitable for significantly increasing the strength of such plate-shaped components (2) zonally through partial material accumulation, in particular...for the formation of permanently joined component connections or for supporting the component and product stability against forces that act on the plate-shaped components (2) from the outside during the manufacturing and assembly process of the product or during the use of the product, and/or which are suitable for equipping such plate-shaped components (2) zonally with function-enhancing elements to the advantage of the manufacturing, assembly process and/or use of the component or end product in a way that is largely invisible from the outside.