Polymer-Filled Sandwich Component Joints for Automated Load Transfer
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Solution Overview
Problem
Commercially available methods for connecting sandwich components are labor-intensive, costly, and limit design flexibility due to the need for manual insertion of reinforcing elements, resulting in high process costs and low reliability.
Innovation Solution
A method using a curable polymer composition injected through an attachment's filling opening to connect a sandwich component, allowing for automated and quick assembly without additional connecting means, with the polymer composition hardening to form a solid bond within the sandwich structure, optimizing force application and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If commercially available punctual force introductions (inserts/onserts) are used to connect sandwich components, then force transmission is achieved, but manual insertion is required leading to high process costs and low automation
Solution Approach 1:
The patent replaces the mechanical insertion system (screws, clips, or other rigid fasteners) with a polymer composition that is injected into the sandwich component. This polymer acts as a bonding agent that cures to form a strong connection, eliminating the need for manual mechanical fastening operations and enabling automated injection processes.
Solution Approach 2:
The patent employs injection technology to introduce the polymer composition into the sandwich component through filling openings. This hydraulic/pneumatic injection system enables automated delivery of the bonding material, replacing manual insertion methods and reducing process costs while improving automation.
2Adaptability or versatility
If standardized connecting means are used for force introductions, then manufacturing is simplified, but product design flexibility and component adaptability are severely limited
Solution Approach 1:
The patent allows for variation in the polymer composition's properties (viscosity, curing time, strength) to match different design requirements. The injection process parameters can also be adjusted to accommodate different component geometries, enabling design flexibility without requiring standardized connecting means for each application.
Solution Approach 2:
The polymer composition serves multiple functions: it acts as a bonding agent, a force distribution medium, and a filling material. This single versatile solution can be adapted to various connection scenarios without requiring different standardized fasteners, thereby improving design flexibility while maintaining manufacturing simplicity.
3Reliability
If manual insertion of inserts or onserts is performed, then connection is achieved, but process reliability is low due to labor-intensive operations
Solution Approach 1:
The patent replaces manual mechanical insertion with an automated injection system that delivers the polymer composition consistently and reliably. This eliminates human error associated with manual fastening operations, improving process reliability while increasing productivity through automation.
Solution Approach 2:
The polymer composition automatically fills the connection space through injection pressure and then cures in place, creating a self-completing connection process. This self-service characteristic eliminates the need for manual positioning and insertion operations, thereby improving both reliability and productivity.
4Strength
If additional connecting means such as screws are used, then firm connection is achieved, but the process becomes more complex and costly
Solution Approach 1:
The patent merges the functions of multiple connecting means (screws, fasteners, bonding agents) into a single polymer composition system. The injected polymer provides both bonding strength and structural support, eliminating the need for separate mechanical fasteners and simplifying the overall connection system while maintaining firm connection.
Solution Approach 2:
The patent uses a composite approach by combining the polymer composition with the sandwich component structure itself. The polymer bonds to both the cover layers and the core, creating a composite connection that leverages the structural characteristics of the sandwich component to achieve firm connection without additional metal fasteners.
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
Enables a reliable, cost-effective, and flexible connection between sandwich components, allowing for optimized force transfer and improved mechanical properties, particularly suitable for dynamic loads, with the polymer composition anchoring deeply into the intermediate layer for enhanced stability.
Implementation Method 1
A curable polymer composition is introduced into the at least one opening of the sandwich component via the first filling opening of the attachment, such that the attachment and the sandwich component are connected to one another by the polymer composition after the polymer composition has hardened.
Data Source
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AI summary
The invention relates to a method for connecting an add-on part (3) to a sandwich component (2). The method comprises the steps: providing a sandwich component (2), providing an attachment (3) with at least one first filling opening (31), joining the attachment (3) to the sandwich component (2) in such a way that the first filling opening (31) of the add-on part (3) and at least one opening (24) of the sandwich component (2) are arranged in a communicating manner. A polymer composition (4) is introduced into the at least one opening (24) of the sandwich component (2) via the first filling opening (31) of the attachment (3) in such a way that the attachment (3) and the sandwich component (2) after curing of the polymer composition (4) are bound together by the polymer composition (4). The invention further relates to the use of a polymer composition (4) and a composite component (1).