Open Area Core Sandwich Panel with High Gloss Surface
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Solution Overview
Problem
Conventional sandwich composite structures face challenges in achieving a high gloss surface without additional processing or outermost layers, and they are prone to moisture infiltration, which can reduce operational lifetime and increase weight, especially when the core is made of cellulosic materials.
Innovation Solution
A composite sandwich panel assembly with an open area core sandwiched between a high gloss surface sheet and a structural skin, adhered using viscous adhesives that fill the pores of the core, providing increased adhesion surface area and preventing delamination, while also incorporating a cloth for enhanced moisture resistance and sound dampening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sandwich composite structures use additional outermost layers or post-production processing to achieve high gloss surface, then surface quality is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the structural skin and high-gloss surface layer into a single integrated component. The skin itself is formulated to provide both structural integrity and high-gloss finish, eliminating the need for separate outermost layers or post-production coating processes. This merging of functions reduces structural complexity while maintaining surface quality.
Solution Approach 2:
The structural skin is designed to serve multiple functions simultaneously: it provides mechanical strength and stiffness as a structural element, while also delivering the high-gloss surface finish typically requiring separate layers. This multi-functionality eliminates additional components and simplifies the overall structure.
2Weight of moving object
If conventional sandwich structures with open area cores are used to reduce weight, then weight savings are achieved, but moisture infiltration increases which reduces reliability and increases weight over time
Solution Approach 1:
The patent employs a skin formulated with hydrophobic materials and surface treatments that create a moisture-resistant barrier. This thin film-like protective layer prevents moisture infiltration through the open area core while maintaining the core's weight-saving porous structure. The skin acts as a flexible barrier that blocks moisture while allowing the lightweight core structure to remain exposed.
3Quantity of substance
If cellulosic materials are used for the core to reduce weight and cost, then manufacturing cost and weight are reduced, but moisture infiltration and delamination increase
Solution Approach 1:
The patent modifies the chemical parameters of the cellulosic core material by applying hydrophobic coatings and surface treatments. These parameter changes alter the material's interaction with moisture, making it water-resistant while preserving the lightweight cellulosic structure. The treatment changes the surface energy and porosity characteristics to prevent moisture absorption.
Solution Approach 2:
The patent creates a composite structure where the cellulosic core is combined with hydrophobic coating materials and adhesive layers. This composite approach maintains the cost and weight advantages of cellulosic materials while adding moisture resistance through the hydrophobic components. The multi-layer composite prevents delamination by using adhesives that bond effectively to both the cellulosic core and the hydrophobic surface layer.
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
The solution achieves a high gloss exterior surface without additional layers, reduces delamination, and provides moisture resistance and sound dampening, extending the operational lifetime and reducing weight of the structure.
Implementation Method 1
The high gloss surface sheet is adhered to the first face of the open area core by a first adhesive layer
Implementation Method 2
adhered using viscous adhesives that fill the pores of the core, providing increased adhesion surface area
Implementation Method 3
incorporating a cloth for enhanced moisture resistance
Implementation Method 4
cloth for enhanced moisture resistance and sound dampening
Data Source
AI summary
A composite sandwich panel assembly including an open area core, a high gloss surface sheet, and a structural skin. The open are core defines a plurality of pores and has a first face and an opposing second face. The high gloss surface sheet is adhered to the first face of the open area core by a first adhesive layer. The high gloss surface sheet has a high gloss surface. The structural skin is adhered to the second face of the open area core by a second adhesive layer. A process for forming the composite sandwich panel assembly includes positioning the high gloss surface sheet, joining the first face of the open area core to the high gloss surface sheet with a first adhesive layer intermediate therebetween, and joining the structural skin to the second face of the open area core with a second adhesive layer intermediate therebetween.