Rail Vehicle Honeycomb Panel Resin Edging
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Solution Overview
Problem
The manufacturing of rail vehicle equipment panels is costly and time-consuming due to the need for expensive operations and complex assembly processes, particularly in shaping and finishing the edges of panels with cellular cores and skins.
Innovation Solution
Introducing resin into the peripheral zone of the panel to both assemble and reinforce the honeycomb core with the skins, while machining the contour to create a continuous surface for easy assembly and gluing of the side skin, thereby simplifying the edging process and reducing manufacturing time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used with separate assembly of edging and molded parts, then structural integrity is maintained, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent merges the edging assembly and molded part assembly into a single integrated operation. The resin injection process simultaneously bonds the edging to the panel core and forms the molded protective parts, eliminating sequential assembly steps and reducing manufacturing time while maintaining structural integrity.
Solution Approach 2:
The resin injection process serves multiple functions simultaneously: it acts as an adhesive to bond the edging, as a structural reinforcement for the panel core, and as a molding material for creating protective parts at the edges. This multi-functionality reduces the number of separate manufacturing operations required.
2Ease of manufacture
If expensive molded parts are used for edging, then structural integrity and finish quality are improved, but manufacturing cost increases
Solution Approach 1:
The patent changes the physical state and properties of the resin material during the manufacturing process. The resin is injected in a liquid state to fill and bond the edging, then cured to form a solid structural component. This parameter change allows a single material to serve multiple functions that traditionally required separate expensive molded parts.
3Strength
If the peripheral zone is fully reinforced with resin, then structural rigidity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies resin reinforcement selectively to specific zones within the panel structure. The edging areas receive concentrated resin injection for maximum structural benefit, while other areas maintain their original construction. This localized approach provides necessary strength without uniformly increasing manufacturing complexity throughout the entire panel.
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 method significantly reduces manufacturing time and costs by creating a structurally rigid panel with a continuous surface finish, allowing for efficient assembly and reducing the need for expensive molded parts, while maintaining or improving the structural integrity of the panel.
Implementation Method 1
the resin is introduced into the peripheral zone, filling the cells of this peripheral zone. Thus, this resin makes it possible both to ensure the assembly of the honeycomb core with the first and second skins, and also reinforces the honeycomb core
Implementation Method 2
The resin is introduced into the peripheral zone, filling the cells of this peripheral zone
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
The equipment panel comprises a honeycomb core (16) sandwiched between first (12) and second (14) skins. The method comprises: assembling the first skin (12) with the honeycomb core (16), the honeycomb core (16) being arranged so that its cells extend perpendicularly to the first skin (12); filling a peripheral area of the honeycomb core (16) with a resin; assembling the second skin (14) with the honeycomb core (16); polymerizing the resin, thus bonding the honeycomb core (16) with the first (12) and second (14) skins; machining a contour (26) of the panel (10), the contour (26) being defined in a plane parallel to the first (12) and/or second (14) skins, and machined in the peripheral area; and the assembly of a side skin on an edge (28) of the panel (10) with the machined contour (26).