Honeycomb Panel Laminate Bonding with Flexible Foam Faces
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Solution Overview
Problem
The bonding between honeycomb materials and face materials in laminates is weak due to the irregular thickness and non-flat edges of hexagonal cell walls, leading to inadequate sound insulation and structural strength, limiting their application in noise control and construction.
Innovation Solution
A method involving the use of flexible sponge foam for both sound absorbing and sound insulating faces, where the honeycomb material is bonded by applying adhesive to the hexagonal edges and applying pressure to bite into the foam, increasing the bonding area and strength, and filling honeycomb cells with open-cell hard phenol foam for enhanced sound absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If rigid face materials with high planar accuracy are used for soundproofing, then sound insulation capability is improved, but bonding strength with honeycomb material deteriorates due to irregular cell wall edges
Solution Approach 1:
The invention changes the physical state and mechanical properties of the face material by using flexible foam material instead of rigid material. This flexibility allows the face material to conform to the irregular honeycomb cell wall edges, creating adequate bonding space and improving adhesion while maintaining sound insulation capabilities through the foam's inherent acoustic properties
Solution Approach 2:
The invention creates a composite structure combining honeycomb material with flexible foam face materials. This composite approach allows each material to contribute its strengths: the honeycomb provides structural framework while the flexible foam provides both bonding compliance and sound absorption/insulation properties, resolving the contradiction between rigid soundproofing requirements and bonding needs
2Ease of manufacture
If adhesive is applied to linear edges of hexagonal cell walls for bonding, then bonding process is simplified, but bonding area is insufficient leading to weak bonding
Solution Approach 1:
The invention transitions from one-dimensional linear edge bonding to two-dimensional surface bonding. By applying adhesive to the entire surface of the flexible foam face material rather than just the linear edges of cell walls, the bonding area is dramatically increased while the flexible foam conforms to the honeycomb structure, maintaining manufacturing simplicity
Solution Approach 2:
The flexibility parameter of the foam material enables it to deform and conform to the irregular honeycomb cell wall edges, allowing the adhesive to spread across a larger effective bonding area. This dimensional expansion of the bonding interface significantly increases bonding strength without complicating the manufacturing process
3Weight of moving object
If honeycomb cell spaces are left hollow for weight saving, then weight is reduced, but sound absorption and heat insulation performance deteriorates
Solution Approach 1:
The flexible foam face materials serve multiple functions simultaneously: they provide bonding compliance to the honeycomb structure, absorb sound through their porous structure, and provide heat insulation through their cellular configuration. This multi-functionality allows the panel to achieve acoustic and thermal performance without significantly increasing weight, as the foam materials are lightweight by nature
Solution Approach 2:
The invention utilizes porous foam materials for the face layers, which inherently provide sound absorption through their cellular structure that traps and dissipates acoustic energy. The same porous structure provides thermal insulation by trapping air pockets, achieving both acoustic and thermal performance while maintaining low weight characteristics of foam materials
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 approach results in a lightweight, robust honeycomb panel laminate with improved sound insulation and structural stability, capable of being used in curved surfaces and exceeding standard sound attenuation and heat insulation performance.
Implementation Method 1
bonding the honeycomb material to the sound absorbing face by applying an adhesive to hexagonal linear edges of cell walls of the honeycomb material
Implementation Method 2
the sound absorbing face being made of a sponge foam
Implementation Method 3
a layer obtained by filling spaces in cells of the honeycomb material with a hard foam material
Data Source
Figure 1~3
Figure 3-1~4
Figure 4-1~4-2
AI summary
[Problem to be Solved] In a laminated material based on a honeycomb material, there has been such a problem that the bonding between a honeycomb material serving as a base and two face materials between which the honeycomb material is sandwiched requires bonding between planar members having great rigidity with a high degree of planar accuracy and honeycomb members that are linear and not completely flat, thus making it to obtain a great deal of bonding force. [Solution] A honeycomb panel laminate includes a sound absorbing face, a sound absorbing layer, and a sound insulating face. The sound absorbing face is made of a foam. The sound absorbing layer is composed of a honeycomb material and a layer obtained by filling spaces with a hard foam material. The honeycomb panel laminate has a structure obtained by bonding the honeycomb material to the sound absorbing face by applying an adhesive to edges of the honeycomb material of the sound absorbing layer and pressing the edges against the sound absorbing face so that the edges bite into the foam. The sound insulating face, which faces the sound absorbing face across the honeycomb material, is made of a foam, and has a bonded structure obtained by applying an adhesive all over a surface of the sound insulating face that makes contact with the honeycomb material and pressing opposite edges of cell walls of the honeycomb material against the sound insulating face so that the opposite edges bite into the surface, all over which the adhesive has been applied, of the foam.