Lightweight Panel Adapter with Ribbed Anchoring for Honeycomb Cores
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Solution Overview
Problem
Existing adapter systems for lightweight panels with honeycomb cores struggle to provide sufficient mechanical stability and anchoring for fastening elements due to the core's lower density compared to the cover panels, leading to inadequate holding forces and limited versatility in applications.
Innovation Solution
An adapter with a rectangular, square, or oval shape featuring radially outward ribs and projections that can be inserted between the cover panels of lightweight panels, creating a stable anchoring volume for fastening elements, which can be secured using ultrasound or adhesive, allowing for flexible use across various panel thicknesses and applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fastening elements are directly attached to lightweight panels with honeycomb cores, then the panel weight remains low, but the mechanical stability and holding forces are insufficient
Solution Approach 1:
The patent introduces an adapter as an intermediary component between the fastening element and the lightweight panel. The adapter features an anchoring volume with ribs that extend into the honeycomb core structure, providing secure mechanical interlocking while the external casing distributes loads to the cover plates. This mediator enables sufficient holding forces without requiring additional panel material or weight.
2Strength
If the adapter is secured using adhesive only, then the installation process is simple, but the anchoring strength in the low-density core is insufficient
Solution Approach 1:
The securing mechanism is segmented into two distinct functions: adhesive bonding for initial positioning and load distribution, and mechanical interlocking via ribs for primary anchoring strength. The ribs extend into the honeycomb core cells, creating physical interlocking that complements the adhesive bond, thereby achieving sufficient anchoring strength without excessive complexity.
3Strength
If multiple fastening elements are distributed over a large area, then the holding forces are sufficient, but the adapter design becomes less versatile for different panel thicknesses
Solution Approach 1:
The adapter design transitions the problem from two-dimensional area distribution to three-dimensional volume utilization. The anchoring volume extends into the panel thickness with ribs that engage multiple honeycomb core layers, providing sufficient holding forces through volumetric anchoring rather than areal distribution. This enables versatility across different panel thicknesses while maintaining adequate anchoring strength.
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 adapter significantly stabilizes lightweight panels by distributing holding forces across the cover panels and core, enabling secure anchoring of multiple fastening elements and transforming the panel into an area similar in stability to solid material, thus enhancing mechanical strength and versatility.
Implementation Method 1
The adapter (10) is subjected to ultrasound (50) so that the radially outwardly directed ribs (20) of the edge section of the casing (16) abutting the first end face (12) and/or the projections (26) projecting from the second end face (14) at least in their edge region perpendicular to the second end face (14) are heated, melt and form a material-to-material bond with the cover panels (32, 34) of the lightweight panel (30).
Data Source
Figure 1~4
Figure 5~9
Figure 10~14
AI summary
The invention relates to an adapter (10) for panels, in particular with two opposing cover areas and a core, wherein the cover areas are mechanically more resilient than the core, in particular for lightweight panels, wherein the lightweight panels have a first cover panel, a second cover panel and a core arranged between the cover panels with a lower density than the cover panels, in particular a honeycomb core, wherein the adapter has a first end face (12), a second end face (14) opposite the first end face and a sleeve (16) extending between the end faces, wherein at least the first end face has a rectangular, square or oval shape.wherein at least one edge section of the mantle abutting the first end face is provided with radially outwardly directed ribs (20) and/or wherein the second end face is provided, at least in its edge region, with projections (26) extending perpendicularly to the end face.