Profiled Metallic Sheet Seal Layout for Stable Sandwich Panels
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Solution Overview
Problem
Existing profiled metallic sheets for sandwich panels experience deformation and delamination issues due to inadequate foam expansion and adhesion within protrusions, leading to air pockets and thermal instability.
Innovation Solution
A profiled metallic sheet design with a longitudinal seal in the protrusion to create an unfillable volume, preventing foam expansion and ensuring adhesion, combined with complementary U-shaped bends for interlocking panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If foam is sprayed between metallic facings without a seal in the protrusion, then the panel can be manufactured with simple structure, but the foam cannot correctly expand inside the protrusion leading to air pockets and deformation
Solution Approach 1:
The protrusion is segmented into two functional zones by the longitudinal seal: an unfillable volume (V) that prevents foam expansion and air pocket formation, and a fillable volume that allows controlled foam expansion. This segmentation resolves the contradiction by creating a simple seal structure that precisely controls foam behavior without complicating the manufacturing process.
Solution Approach 2:
The longitudinal seal acts as an intermediary element between the foam and the protrusion interior. It mediates the interaction by blocking foam penetration into the unfillable volume while allowing the protrusion to maintain its structural integrity, thus preventing deformation without requiring complex foam expansion control mechanisms.
2Strength
If adhesion promoter is added between metallic facings and foam, then adhesion is improved, but the adhesion promoter cannot penetrate inside the protrusion resulting in foam delamination
Solution Approach 1:
The protrusion is segmented into an unfillable volume (blocked by the seal) and a fillable volume. The adhesion promoter is applied only to the metallic facing within the fillable volume where it can effectively penetrate and bond with the foam, while the unfillable volume prevents foam expansion that would compromise adhesion. This segmentation resolves the contradiction by ensuring adhesion promoter effectiveness without compromising protrusion stability.
Solution Approach 2:
The unfillable volume is extracted as a foam-free zone from the protrusion. By removing the foam from this specific region, the adhesion promoter can effectively bond to the metallic facing in the remaining fillable volume without being compromised by foam expansion, thus ensuring reliable adhesion while maintaining protrusion integrity.
3Manufacturing precision
If a foam tape is stuck on the metallic facing ahead of profiling, then foam positioning is improved, but the foam tape only adheres to one internal face allowing foam flow and delamination
Solution Approach 1:
The protrusion is segmented into an unfillable volume (blocked by the seal) and a fillable volume. The longitudinal seal provides a reliable barrier that prevents foam flow along the metallic facing, while the adhesion promoter is effectively applied to the metallic facing within the fillable volume. This segmentation resolves the contradiction by ensuring both precise foam positioning and reliable adhesion without the delamination issues of foam tape.
Solution Approach 2:
The longitudinal seal serves as a more effective intermediary than foam tape, providing a reliable barrier that completely prevents foam flow. Combined with the adhesion promoter applied to the metallic facing, it creates a dual-mechanism system that ensures both precise foam positioning and reliable adhesion, eliminating the delamination problem associated with foam tape.
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
Prevents deformation and delamination of protrusions by ensuring proper foam adhesion and stability, enhancing thermal performance and structural integrity.
Implementation Method 1
a longitudinal seal (12) located in the protrusion (8) away from its free end (11) and compressed between the lateral walls (9, 10) of the protrusion (8), thus delimiting an unfillable volume (V) in said protrusion
Implementation Method 2
manufacture the panel by spraying liquid foam between the external and internal metallic facings, said foam thus expanding between them
Implementation Method 3
as the adhesion promoter usually added between the metallic facings and the foam cannot penetrate inside the protrusion, the foam does not correctly adhere to the inside walls of the protrusion
Implementation Method 4
during thermal expansion of the panel, they deform locally the protrusion
Data Source
AI summary
A panel extending along a longitudinal axis (X) and including a profiled metallic tray (15), a profiled metallic sheet (1) and an insulation material (16) sandwiched between the profiled metallic tray (15) and the profiled metallic sheet (1), the profiled metallic sheet (1) including in cross-section perpendicular to the longitudinal axis (X) at least a main part (3) substantially lying down in a plane P and a lateral flange (7) extending inwards from an extremity of the main part (3) and including a U-shaped bend forming a protrusion (8) extending outwards and delimited by two lateral walls (9, 10) and a free end (11), wherein the panel (2) includes a longitudinal seal (12) located in the protrusion (8) away from its free end (11) and compressed between the lateral walls (9, 10) of the protrusion (8), thus delimiting an unfillable volume (V) in the protrusion (8).