Filled Metal Sandwich Structure Angular Sand Compaction
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Solution Overview
Problem
Existing metal sandwich structures face challenges in achieving stability without disproportionately increasing weight, and current filling materials like round sand do not effectively enhance compressibility and density.
Innovation Solution
Filling the channels of a metal sandwich structure with a pourable filler material, such as angular quartz sand, and compacting it using specific vibration frequencies to increase compressive strength and stability, while maintaining a lightweight design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If channels are filled with conventional round sand or foam materials, then density is increased, but compressive strength and stability are not sufficiently improved
Solution Approach 1:
The patent changes the shape parameter of the filler material from round to angular, and optimizes particle size distribution (0.03-0.6mm), transforming the physical characteristics of the filling material to achieve better compaction and higher compressive strength without increasing weight
Solution Approach 2:
The patent uses angular quartz sand as a composite filler material that combines the advantages of angular shape (better interlocking and compaction) with appropriate particle size distribution, creating a more effective filling solution than conventional round sand or foam materials
2Stability of the object's composition
If angular filler material is used to improve compressive strength, then stability increases, but weight may increase
Solution Approach 1:
The patent optimizes the particle size parameters of the angular filler material to 0.03-0.6mm, which allows for efficient compaction and high density achievement with minimal material quantity, thereby increasing stability without disproportionate weight increase
Solution Approach 2:
The patent utilizes the void spaces between angular particles as a lightweight structural feature, where the angular shape allows for better interlocking and load distribution while maintaining porosity that prevents excessive weight gain
3Strength
If only one channel is filled with material, then some stability is improved, but manufacturing complexity increases due to distinguishing filled and unfilled channels
Solution Approach 1:
The patent merges the filling operation into a single universal step where both channels are filled simultaneously with the same angular material, eliminating the need to distinguish between filled and unfilled channels and simplifying the manufacturing process while maximizing stability
4Ease of manufacture
If conventional filler materials are used, then manufacturing is simple, but acoustic damping and sound insulation are insufficient
Solution Approach 1:
The patent changes the shape parameter of the filler from round to angular, which creates irregular interfaces and scattering paths for sound waves, significantly improving acoustic damping and sound insulation properties while maintaining manufacturing simplicity
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 proposed solution significantly enhances the stability and acoustic damping of the metal sandwich structure without significantly increasing its weight, while simplifying the manufacturing process and improving sound insulation.
Implementation Method 1
compacting it using specific vibration frequencies to increase compressive strength and stability
Implementation Method 2
An angular material is used as the pourable filler. Crushed or crushed sand, for example, can be used. The advantage of using an angular material, especially sharp-edged sands, compared to non-angular materials like rounded sands, is that it can be compressed much more efficiently and to a greater degree, resulting in fewer voids in the channels.
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a metal sandwich structure comprising a first and a second outer layer and a core layer arranged between the first and second outer layers, which has a corrugated structure. First channels are formed through the first outer layer and the core layer, and second channels are formed through the second outer layer and the core layer, wherein at least the first and/or the second channels are filled with a pourable filler material.