Pultruded Sandwich Panel Profile With Signal-Transparent Core Windows
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Solution Overview
Problem
The introduction of a core material into pultruded profiles can significantly lower mechanical characteristics and increase manufacturing costs, while existing pultrusion systems lack the ability to create localized functionalities in a composite structure without compromising the continuous nature of the process.
Innovation Solution
A pultrusion method that incorporates discrete core elements with varying shapes and materials between surface layers, forming a sandwich structure to create localized functionalities such as signal windows, while maintaining the continuous production process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional extrusion methods are used to manufacture uPVC panel profiles, then manufacturing simplicity is maintained, but warping and twisting occur during cooling due to non-uniform thickness
Solution Approach 1:
The extrusion die is segmented into multiple heating zones with independent temperature control, allowing different sections of the profile to be cooled at different rates. This segmentation enables precise control over the cooling process to prevent warping and twisting while maintaining manufacturing simplicity.
Solution Approach 2:
Different sections of the profile receive localized cooling treatments through the multi-zone die system. Thicker sections are cooled more slowly while thinner sections cool faster, creating local quality variations in the cooling rate that match the thickness distribution and prevent dimensional instability.
2Manufacturing precision
If conventional cooling methods are used after extrusion, then manufacturing process simplicity is maintained, but warping and twisting occur due to non-uniform cooling
Solution Approach 1:
The cooling process is initiated within the extrusion die itself through integrated cooling channels, rather than after extrusion. This preliminary cooling action begins immediately as the profile is formed, preventing warping and twisting before they can occur during subsequent cooling stages.
Solution Approach 2:
Coolant flowing through channels in the extrusion die acts as an intermediary medium to transfer heat from the profile to the die structure. This intermediary cooling system enables controlled, uniform heat removal that prevents thermal gradients causing warping and twisting.
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 the production of composite panels with enhanced mechanical properties and localized functionalities, such as signal transparency, without increasing manufacturing costs.
Implementation Method 1
a multi-zone die which cools different sections of an extruded profile at different rates
Data Source
Figure 1~2
Figure 3a~3b
Figure 3c
AI summary
The present disclosure describes a pultruded panel profile (40) with a sandwich structure and a method of manufacturing such a panel profile. The sandwich structure has at least one a core layer (42) and surface layers (44) on both sides of the sandwich structure. The core layer (42) comprises at least one signal window section (46) made of a signal-transparent material, the signal-transparent material being substantially transparent to at least one wireless signal. The core layer further comprises a peripheral section (48a, 48b) surrounding the signal window section (46), the peripheral section (48a, 48b) having a different material composition than the signal window section (46).