Foam Glass Composite Panel for Vehicle Interiors
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Solution Overview
Problem
Existing composite panels for vehicle interior fittings face challenges in achieving low mass while maintaining high flexural rigidity, panel strength, fire protection, and noise insulation, with brittle expanded glass cores being particularly sensitive to loads and temperature stresses.
Innovation Solution
A composite panel design featuring a low-density expanded glass support core with a ductile or elastic adhesive connecting a metallic cover layer, allowing for load distribution and decoupling of structure-borne noise, and using a segmented core to manage bending stresses, along with a silicone adhesive for enhanced elasticity and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If a brittle expanded glass support core is used to achieve low mass and high rigidity, then the panel mass is reduced and flexural rigidity is improved, but the panel strength deteriorates due to low elongation at break and sensitivity to loads
Solution Approach 1:
The patent uses a composite structure combining brittle expanded glass granules as support core with ductile adhesive and metallic cover layers. This composite approach allows the system to benefit from the low mass and high rigidity of expanded glass while the ductile adhesive and metal layers compensate for the brittleness, providing overall panel strength and load-bearing capacity.
Solution Approach 2:
The patent changes the mechanical parameters of the adhesive layer by selecting ductile or elastic adhesive materials with specific rheological properties. This allows the adhesive to deform plastically or elastically under load, absorbing energy and preventing stress concentration in the brittle expanded glass core, thereby improving overall panel strength.
2Weight of stationary object
If a brittle expanded glass support core is used to achieve low mass, then the panel mass is reduced, but the panel reliability deteriorates due to sensitivity to point loads and temperature stresses
Solution Approach 1:
The ductile or elastic adhesive layer acts as a cushioning element that is already in place before loads are applied. When point loads or temperature stresses occur, the adhesive deforms plastically or elastically, absorbing and distributing the stresses before they can reach the brittle expanded glass core, thereby preventing damage and maintaining panel reliability.
Solution Approach 2:
The adhesive layer serves as an intermediary between the metallic cover layers and the expanded glass support core. It mediates the transmission of loads and temperature stresses, protecting the brittle core from direct exposure to mechanical and thermal stresses while allowing the cover layers to provide structural protection.
3Strength
If a one-sided cover layer is used to absorb bending loads, then the panel strength is improved, but the device complexity increases due to asymmetric structure requirements
Solution Approach 1:
The patent employs asymmetric structure design where only one side of the panel has a cover layer, while the other side has only the expanded glass support core. This asymmetric configuration is optimized for absorbing bending loads in specific directions, providing sufficient panel strength while avoiding the complexity of requiring cover layers on both sides.
4Strength
If a stiff adhesive is used to attach cover layer to support core, then the connection strength is improved, but the panel reliability deteriorates due to inability to accommodate differential expansion and stress distribution
Solution Approach 1:
The patent changes the rheological parameters of the adhesive by selecting ductile or elastic materials with specific viscosity and deformation characteristics. This allows the adhesive to maintain strong connection while simultaneously deforming to accommodate differential thermal expansion and stress distribution, preventing connection failure under varying conditions.
Solution Approach 2:
The adhesive layer is designed to be dynamic rather than static, capable of deforming plastically or elastically in response to changing loads and temperature conditions. This dynamic behavior allows the adhesive to maintain reliable connection strength while adapting to stress distribution and thermal expansion, preventing cracking and delamination.
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 results in a panel that can absorb higher loads, offers improved soundproofing, reduced weight, and enhanced fire protection, with a 28% weight savings compared to prior art while maintaining superior mechanical properties and sound insulation.
Implementation Method 1
the adhesive layer is elastic or at least ductile and thus enables elastic or ductile behavior between the cover layer on the one hand and the supporting core on the other hand
Implementation Method 2
Ductility is understood as meaning the property of the adhesive to initially undergo strong plastic deformation when overloaded before it fails
Implementation Method 3
It also reduces temperature stresses as a result of unequal temperature expansion coefficients of the cover layer on the one hand and the support core on the other
Implementation Method 4
In order to achieve good thermal insulation properties, e.g. Expanded glass, expanded clay, expanded perlite and similar recommended
Implementation Method 5
the soft bedding leads to an improved force distribution of loads that act on the support core composite panel via the cover layer
Data Source
Figure 1
Figure 2~3
AI summary
The invention relates to a supporting core composite panel (1) for internal enlargements, particularly for watercraft, having a supporting core (2) made of foam glass, having at least one cover layer (4, 4.1, 4.2), which largely covers the entire surface of the supporting core (2) on at least one side (2.1, 2.2), having an elastic adhesive material (3, 3.1, 3.2) that fastens the cover layer (4, 4.1, 4.2) on the supporting core (2).