Expandable Framework in Sandwich Panels for Structural Support
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Solution Overview
Problem
There is a need for sandwich panels with enhanced structural support and variable core functionality that do not require a curing process or can be formed using an out-of-autoclave process, particularly for applications like aerospace where traditional sandwich panels may lack sufficient structural support and flexibility.
Innovation Solution
The development of reinforced sandwich panels featuring two skin panels with a foam core and an expandable framework within the foam core, which can expand from a collapsed to an expanded state, providing enhanced structural support and allowing for on-site formation without the need for curing, using materials such as metals, ceramics, or thermoplastic materials for the framework and thermoset or thermoplastic materials for the skin panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional sandwich panels are used, then weight reduction is achieved, but structural support is insufficient
Solution Approach 1:
The patent employs a composite structure combining foam core material with an expandable framework made of metal, ceramic, or thermoplastic materials. This composite approach integrates the lightweight properties of foam with the structural strength of the framework, resolving the contradiction between weight reduction and structural support enhancement.
Solution Approach 2:
The expandable framework transitions from a collapsed state during manufacturing/transport to an expanded state during operation. This dynamic transformation allows the panel to achieve enhanced structural support only when needed, while maintaining lightweight properties during storage and transportation phases.
2Reliability
If curing process is required, then structural integrity is improved, but manufacturing complexity and time increase
Solution Approach 1:
The expandable framework provides self-supporting capability through its expansion mechanism, eliminating the need for external curing processes or autoclave equipment. The framework's structural integrity is achieved through its own geometric configuration and material properties rather than requiring chemical curing or external pressure treatment.
Solution Approach 2:
The patent replaces the chemical/thermal curing process with a mechanical expansion mechanism. Instead of using heat, pressure, or chemical reactions to achieve structural integrity, the framework uses mechanical transformation from collapsed to expanded state, simplifying the manufacturing process and enabling out-of-autoclave production.
3Strength
If expandable framework is added, then structural support and conductivity are enhanced, but device complexity increases
Solution Approach 1:
The expandable framework simultaneously performs multiple functions: providing structural support through its expanded geometry, enhancing thermal conductivity through continuous material pathways, and improving electrical conductivity through the framework material itself. This multi-functionality reduces the need for separate components, thereby limiting the increase in overall device complexity.
Solution Approach 2:
The patent merges the structural support function, thermal management function, and electrical conductivity function into a single integrated expandable framework component. This consolidation approach enhances performance across multiple parameters while avoiding the complexity increase that would result from adding separate systems for each function.
4Adaptability or versatility
If panels are formed on-site, then adaptability and logistics are improved, but manufacturing precision may deteriorate
Solution Approach 1:
The framework is manufactured and pre-configured in a collapsed state with precise dimensions and geometry before transportation. This preliminary manufacturing ensures high precision is achieved during fabrication, while the collapsed configuration enables easy transport and on-site deployment without compromising the pre-established dimensional accuracy.
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 provides improved structural support and flexibility, enabling the panels to maintain a predetermined distance between skin panels, enhancing thermal and electrical conductivity, and allowing for on-site assembly, reducing manufacturing complexity and costs while meeting the demands of aerospace applications.
Implementation Method 1
The expandable framework can resiliently expand from a collapsed state to an expanded state
Implementation Method 2
one or more adhesive layers, wherein the one or more adhesive layers bond at least one of the foam core and the expandable framework to the two skin panels
Implementation Method 3
a flexible film, wherein the foam core can be encapsulated by the flexible film, and wherein the flexible film can bond the foam core to at least one of the skin panels or the expandable framework
Data Source
AI summary
A reinforced sandwich panel, including two skin panels; a foam core disposed between the two skin panels; and an expandable framework disposed within the foam core.