Metallic Sandwich Panel with Spacer Unit for Lightweight Construction

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Solution Overview

Problem

Existing hollow extruded cement panels are too heavy, require a lengthy curing process, and are prone to cracking or peeling, making them difficult to install and maintain.

Innovation Solution

A sandwich panel design featuring a metallic first and second plate member, a metallic spacer unit in the shape of a rectangular frame, and a core member, where the spacer unit and core member are bonded to the plate members, reducing weight and eliminating the need for curing while enhancing strength and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If hollow extruded cement plate is used, then panel strength is improved, but weight increases and installation difficulty increases

Engineering Contradiction:

Improvepanel strengthVSAvoidpanel weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The invention uses a composite structure combining metallic plate members with a core member filled with lightweight material (foam, fiber, or granular material). This composite approach maintains structural strength while significantly reducing weight compared to solid cement plates.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The core member is strategically placed only in specific regions between the plate members rather than filling the entire panel volume. This localized approach provides sufficient structural support where needed while minimizing overall weight.

Inventive Principle:

Principle #3Local quality

2Reliability

If hollow extruded cement plate is used, then panel durability is improved, but manufacturing complexity increases due to curing process

Engineering Contradiction:

Improvepanel durabilityVSAvoidmanufacturing process simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention replaces the chemical curing process of cement with mechanical bonding methods. The metallic plate members are bonded to the core member using adhesives or mechanical fasteners, eliminating the need for time-consuming curing while maintaining structural integrity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The invention changes the material parameters from cement-based composite requiring curing to metallic components with mechanical bonding capabilities. This parameter change transforms the manufacturing process from chemical-setting to mechanical-assembly, significantly reducing production time.

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If hollow extruded cement plate is used, then panel integrity is improved, but susceptibility to cracking and peeling increases

Engineering Contradiction:

Improvepanel integrityVSAvoidresistance to cracking and peeling

Core Design Contradiction:

Stability of the object's compositionVSReliability

Solution Approach 1:

The metallic plate members combined with the resilient core member create a composite structure that accommodates thermal expansion and contraction differently, reducing stress concentrations that lead to cracking and peeling in monolithic cement plates.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Changing from a homogeneous cement material to a composite of metallic plates and flexible core material alters the mechanical properties, providing better flexibility and resistance to cracking while maintaining overall structural integrity.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If metallic plate members with spacer unit and core member are used, then weight is reduced and ease of manufacture is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidbonding alignment precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The spacer unit acts as an intermediary component between the plate members and core member, providing built-in positioning features and bonding surfaces that simplify alignment during assembly, thereby reducing the precision requirements for manual positioning.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The spacer unit and core member are prepared in advance with pre-formed bonding surfaces and alignment features, so that during final assembly, the components naturally align without requiring high-precision positioning operations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS10774525B2Sandwich panel

Publication Date: 2020.09.15 NIPPON STEEL COATED SHEET CORP

AI summary

A sandwich panel includes a first plate member and a second plate member, each of which is metallic, a spacer unit which is metallic and formed in the shape of a rectangular frame, and a core member. The core member is arranged in a region surrounded with the spacer unit between the first plate member and the second plate member. The spacer unit is made up of a plurality of spacers that are formed as separate members. The first plate member and the second plate member are bonded to the core member and each of the plurality of spacers.