Modular Sandwich Panel with Interlocking Loop Core
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Solution Overview
Problem
Existing sandwich panels are difficult to disassemble and reassemble efficiently for transportation and on-site construction, limiting their flexibility and practicality in building applications, especially in disaster recovery scenarios where rapid assembly and reuse are necessary.
Innovation Solution
A sandwich panel design featuring a core with angled loops and spacers that allow for easy assembly and disassembly, enabling the panels to be transported in a compact state and expanded on-site, with skin layers that can be easily attached and detached, and the option to use mesh or panel skin layers for varying applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sandwich panels are designed with traditional rigid connections, then structural strength is improved, but ease of assembly and disassembly deteriorates
Solution Approach 1:
The sandwich panel is divided into separable components: skin layers with loop elements and a core with engaging protrusions. This segmentation allows the panel to be assembled by simply engaging these pre-formed components without complex fastening operations, resolving the contradiction between structural integrity and ease of assembly.
Solution Approach 2:
The loop elements on the skin layers are designed to nest over the engaging protrusions on the core elements. This nested configuration provides a secure mechanical connection that maintains structural strength while allowing for simple engagement and disengagement operations.
2Stability of the object's composition
If sandwich panels are designed as complete assembled units, then structural integrity is improved, but ease of transport deteriorates
Solution Approach 1:
The sandwich panel system is segmented into modular components (skin layers with loops, core elements with protrusions) that can be transported separately in compact forms. These segments are designed to be quickly assembled into complete panels with full structural integrity at the destination, resolving the contradiction between maintaining structural integrity and facilitating easy transport.
3Manufacturing precision
If sandwich panels use complex connection mechanisms, then assembly precision is improved, but device complexity deteriorates
Solution Approach 1:
The connection mechanism is segmented into simple, pre-formed geometric features (loops and protrusions) rather than complex adjustable mechanisms. This segmentation provides inherent alignment and positioning capabilities that ensure assembly precision while keeping the overall device complexity low.
Solution Approach 2:
The loop and protrusion design enables self-aligning and self-positioning during assembly. The geometric features guide the components into proper alignment automatically, eliminating the need for complex alignment mechanisms or tools, thus achieving high assembly precision with minimal device complexity.
Data Source
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AI summary
The invention relates to a sandwich panel, comprising: -a core,comprising: -a plurality of zigzag-shaped first spacers extending in a first longitudinal direction, each first spacer comprising at each corner thereof a first loop; -a plurality of zigzag-shaped second spacers extending in the first longitudinal direction, each second spacer comprising at each corner thereof a second loop, each second loop having outer dimensions that are smaller than the inner dimensions of each first loop, -wherein the second loops of each second spacer extend through the first loops of an adjacent first spacer; -wherein the openings defined by the second loops of successive second spacers are registered in rows extending in a second longitudinal direction, which second longitudinal direction extends under an angle of at least 20° with respect to the first longitudinal direction; and -wherein the first spacers and the second spacers define a second zigzag-shape in the second longitudinal direction; -two skin layers arranged on opposite sides of the core, wherein each skin layer comprises a plurality of openings through which the second loops extend; -a plurality of rods, each rod extending through the openings of the second loops of each row at the outer surface of each skin layer such that each rod locks the second loops in the first loops with respect to the skin layer. The invention further relates to a method of building such a sandwich panel,a core of such a sandwich panel, and a building built of a plurality of such sandwich panels.