Honeycomb Panel Adhesive Application via Net-Like Spraying
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Solution Overview
Problem
Existing methods for manufacturing honeycomb panels result in inefficient adhesive use and complex processes due to adhesive application on cover layers, leading to unused adhesive in cell openings and narrow contact areas between core and cover layers.
Innovation Solution
Spray hot-melt adhesive onto the core element's surface, stretching it to form a net-like structure that concentrates on the webs, then reactivate it by heating, ensuring adhesive is only applied where it contributes to bonding, eliminating the need for extensive drying processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is applied over the entire surface of the cover layers, then adhesion between cover layers and core element is improved, but adhesive consumption increases and adhesive remains unused in the opening areas of the cells
Solution Approach 1:
The adhesive is applied locally only to the web areas of the core element rather than uniformly across the entire surface. The spraying device with movable nozzle directs adhesive precisely onto the webs, ensuring adhesion is concentrated where it is needed for bonding, while avoiding waste in the cell opening areas.
2Strength
If adhesive is applied to cover layers, then bonding between core element and cover layers is achieved, but the contact areas are limited to narrow web regions
Solution Approach 1:
Instead of applying adhesive to the cover layers as in conventional methods, the adhesive is applied to the core element's web surfaces. This inversion of the application surface allows the adhesive to be distributed over the entire web area including lateral surfaces, creating extended contact areas between the core element and cover layers.
3Reliability
If liquid adhesive is used and extended drying time is required, then good adhesion is achieved, but production time increases
Solution Approach 1:
The adhesive applied to the core element undergoes a phase transition from liquid to solid through evaporation of the carrier liquid. This phase change allows the adhesive to quickly set and form strong bonds without requiring extended drying times, enabling faster production cycles.
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
Reduces adhesive consumption and enhances bonding strength by concentrating adhesive on the webs, allowing immediate processing and eliminating energy-intensive drying steps.
Implementation Method 1
Heating the at least one surface of the core element provided with hot-melt adhesive and thereby reactivating the hot-melt adhesive
Implementation Method 2
Spraying a hot-melt adhesive onto at least one surface of the core element
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to a method for producing a honeycomb panel, wherein the honeycomb panel comprises a first cover layer (1) and a second cover layer (2) and a core element (3) arranged between the first cover layer (1) and the second cover layer (2), wherein the core element (3) has a honeycomb structure with cells (5) delimited by webs (4) and wherein the core element (3) has a first surface (6) which bears against the first cover layer (1) and a second surface (7) which bears against the second cover layer (2), comprising the following steps: i) providing the core element (3) and the first and second cover layers (1, 2); ii) spraying a hot-melt adhesive (8) onto at least one surface (6, 7) of the core element (3), wherein the hot-melt adhesive (8) is stretched during spraying so that a net-like adhesive structure (9) is formed on the at least one surface (6, 7) of the core element (3);iii) heating the at least one surface (6, 7) of the core element (3) provided with hot-melt adhesive (8) and thereby reactivating the hot-melt adhesive (8); iv) pressing a cover layer (1, 2) onto the at least one surface (6, 7) of the core element (3) provided with hot-melt adhesive (8); v) optionally carrying out method steps ii) to iv) for the second surface (7) of the core element (3) and the second cover layer (2), so that the core element (3) is arranged between the two cover layers (1, 2);