Flexible Core Layer for Sandwich Composite Tolerance Compensation

Solution Overview

Problem

The manufacturing of sandwich composite components faces challenges in maintaining precise tolerance dimensions and ensuring a strong adhesive bond between the core and cover layers, particularly under extreme stress, which can lead to rigidity and strength loss and component failure.

Innovation Solution

A core layer composed of flexible core elements that can be variable in longitudinal extent, allowing for elastic deformation to compensate for length deviations and adapt to complex shapes, combined with resin channels for controlled resin flow, enabling flexible and rigid core elements to be joined without cavities and ensuring uniform properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If core material with tight tolerance is used to maintain manufacturing precision, then manufacturing precision is improved, but device complexity and ease of manufacture deteriorate

Engineering Contradiction:

Improvetolerance dimensionVSAvoidease of manufacture

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent changes the physical state of the core material from rigid to flexible, allowing it to be deformable. This enables the core to adapt to tolerance variations through elastic deformation rather than requiring precise dimensional control during manufacturing, thereby improving manufacturing precision while simplifying the manufacturing process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The core material is designed with dynamic flexibility, allowing it to change shape and adapt during the bonding process. The flexible core can be deformed to match mold tolerances and then maintains the desired shape after bonding, resolving the contradiction between precision requirements and manufacturing ease

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If flexible core elements are used to compensate for length deviations, then adaptability is improved, but manufacturing precision deteriorates

Engineering Contradiction:

ImproveadaptabilityVSAvoidlength deviation

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The flexible core elements are pre-designed with specific flexibility characteristics and geometric configurations that enable them to compensate for anticipated length deviations. This preliminary design allows the core to automatically adapt to dimensional variations during assembly without compromising the final precision of the bonded component

Inventive Principle:

Principle #10Preliminary action

3Strength

If resin infusion process is used to bond core and cover layers, then strength is improved, but manufacturing precision deteriorates

Engineering Contradiction:

Improveadhesive bond strengthVSAvoidtolerance dimension

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent changes the physical state of the core material from rigid to flexible, allowing it to be deformable. This enables the core to adapt to tolerance variations through elastic deformation rather than requiring precise dimensional control during manufacturing, thereby improving manufacturing precision while simplifying the manufacturing process

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The core material is designed with dynamic flexibility, allowing it to change shape and adapt during the bonding process. The flexible core can be deformed to match mold tolerances and then maintains the desired shape after bonding, resolving the contradiction between precision requirements and manufacturing ease

Inventive Principle:

Principle #15Dynamics

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

This solution allows for precise tolerance compensation and improved bonding within the core and cover layers, enhancing the structural integrity and adaptability of sandwich composite components, facilitating the production of complex shapes and maintaining mechanical properties.

Implementation Method 1

allowing for elastic deformation to compensate for length deviations and adapt to complex shapes

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

combined with resin channels for controlled resin flow

Methodology Applied

Scientific EffectFluid flow through channels:

Data Source

PatentEP2682537B1Core layer for a sandwich composite component, sandwich composite component and method for producing a sandwich composite component

Publication Date: 2020.01.01 GAUGLER & LUTZ

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AI summary

Core element (1) for a core layer (3) of a sandwich composite component (10), is claimed, where the core element shaped surface is arranged with a first main surface (11), a second main surface (12) and side surfaces (13). At least one undercut recess open toward first and/or second major surfaces. Independent claims are also included for: (1) a core layer for a sandwich composite component, where several core elements are arranged in planar manner; and (2) a sandwich composite component comprising a core layer and a cover layer provided with at least one of the major surfaces.