Core element for sandwich elements, use of such a core element, and method for producing such a core element
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Solution Overview
Problem
Existing sandwich elements lack sufficient compressive stability and ease of production, with traditional core materials being difficult to manufacture and prone to distortion, and they often require additional cover layers for stability.
Innovation Solution
A core element comprising two or more hemisphere panels with uniformly shaped elevations, where the outer surfaces of these elevations are sectionally shaped as hemispheres or sphere segments, providing high compressive stability and allowing for easy production without the need for additional cover layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional core materials (solid material, foam, honeycomb lattice) are used, then the sandwich element can be produced, but the compressive stability is insufficient and additional cover layers are required
Solution Approach 1:
The core element uses a three-dimensionally structured core with hemispherical protrusions instead of flat planar surfaces. The curved hemispherical geometry provides inherent compressive stability and load distribution, eliminating the need for additional cover layers while maintaining structural integrity.
2Ease of manufacture
If traditional core materials are used, then the sandwich element can be assembled, but the production process is difficult and prone to distortion
Solution Approach 1:
The core is divided into multiple modular core segments, each with hemispherical protrusions. These segments can be independently manufactured with precise geometry and then assembled together, reducing overall distortion and simplifying the production process compared to manufacturing a single large core piece.
Solution Approach 2:
The invention changes the geometric parameters of the core from flat planar surfaces to three-dimensional hemispherical protrusions. This parameter change enables easier manufacturing through molding processes while maintaining dimensional stability and reducing distortion during assembly.
3Strength
If the core element is designed with high compressive stability, then structural integrity is improved, but the production complexity increases
Solution Approach 1:
The hemispherical protrusions are designed with optimal radius and spacing parameters that provide high compressive stability while being manufacturable using standard molding techniques. The curvature radius is chosen to balance structural performance with ease of production.
Data Source
AI summary
Core element for sandwich elements, wherein the core element has at least two hemisphere panels which are combined with one another, wherein each hemisphere panel has, between planar portions, and spaced apart from one another, uniform hemispherical elevations, wherein the two or in each case two hemisphere panels face one another by way of their elevations, wherein, with two or in each case two hemisphere panels combined with one another, the elevations of one hemisphere panel each bear with their apexes or apex surfaces against a planar portion of the other hemisphere panel, and wherein two hemisphere panels are connected to one another by virtue of the elevations being connected, in the region of their apexes or apex surfaces, to the planar portion of the other or another hemisphere panel against which they bear. Moreover, the invention also relates to the use of a core element and to a method for producing a core element.