Lightweight Panel Edge Formation via Potting Compound Injection

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Solution Overview

Problem

Existing methods for producing lightweight construction elements struggle to eliminate the need for edge bands, particularly when using honeycomb panels, and are limited in creating shaped components with high stability and aesthetic appeal.

Innovation Solution

Introducing a casting compound into a finished sandwich structure of cover layers and an intermediate layer, allowing the component to be cut out with the compound forming a visible edge that replaces the need for edge bands, and enabling the creation of both panel-shaped and shaped lightweight components with enhanced stability and optical appeal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If edge banding is used to cover cut edges of lightweight panels, then the aesthetic appearance is improved, but the manufacturing complexity and difficulty of permanent attachment increase

Engineering Contradiction:

Improveedge appearanceVSAvoidedge banding attachment process

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The potting compound injection process merges multiple functions: it seals the honeycomb structure, creates the visible edge, and provides structural reinforcement simultaneously. This eliminates the need for separate edge banding operations and their associated attachment difficulties.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts the edge covering function from the separate edge banding operation and integrates it into the potting compound injection process. The potting compound itself becomes the visible edge, removing the need for additional attachment steps.

Inventive Principle:

Principle #2Taking out (Extraction)

2Strength

If reinforcing material is introduced before cutting lightweight panels, then the structural strength is improved, but the manufacturing process complexity increases

Engineering Contradiction:

Improvepanel structural strengthVSAvoidmanufacturing process steps

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The potting compound injection process combines structural reinforcement, edge sealing, and edge formation into a single operation performed after cutting. This eliminates the need for separate reinforcing material introduction steps before cutting.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Instead of reinforcing the panel before cutting (as in conventional methods), the invention performs the reinforcement operation after cutting by injecting potting compound into the cut edges. This reverses the sequence and simplifies the process.

Inventive Principle:

Principle #13The other way round (Inversion)

3Shape

If standard edge banding is applied to honeycomb panels, then the edge coverage is achieved, but the permanent attachment becomes difficult

Engineering Contradiction:

Improveedge coverageVSAvoidattachment permanence

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The potting compound simultaneously achieves edge coverage and creates permanent attachment by filling the honeycomb cells and bonding to the face sheets. This integrated approach eliminates the attachment reliability issues of separate edge banding.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The potting compound creates a composite structure by bonding with the existing sandwich panel materials (honeycomb core and face sheets), forming a unified, permanently attached edge structure that cannot be easily separated.

Inventive Principle:

Principle #40Composite 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 method allows for the production of lightweight components with a seamless, visually appealing edge and increased stability, eliminating the need for edge bands and enabling the creation of both flat and curved, dimensionally stable components.

Implementation Method 1

the potting compound is introduced into the lightweight panel when a finished sandwich structure already exists

Methodology Applied

Scientific EffectInjection: Injector

Implementation Method 2

Polyurethane, especially two-component polyurethane mixed in a nozzle, can be used as the potting compound

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentEP3396080B1Method for producing a lightweight element

Publication Date: 2019.11.20 ROSS DESIGN

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AI summary

The invention relates to a method for manufacturing a lightweight component (10) comprising the following process steps: a. Manufacturing a lightweight panel (1) comprising the following steps: i. Bonding a first top layer (2) to an intermediate layer (3); ii. Removing the intermediate layer (3) at predetermined areas; iii. Bonding a second top layer (4) to the intermediate layer (3); iv. Filling at least part of the removed areas with a potting compound; b. Cutting the lightweight component (10) out of the lightweight panel (1).