Sandwich Component Polymer Insert for Direct Force Introduction
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Solution Overview
Problem
Existing sandwich construction methods face challenges with inefficient force transmission, high material consumption, and limited flexibility due to manual insertion of force-introducing elements, which restricts the loading capacity and increases process costs and reliability issues.
Innovation Solution
A sandwich component with a crosslinked polymer composition injected between the covering layers, allowing for direct fixation of mechanical connecting means, optimizing force introduction and distribution, and enabling automated force introduction and removal without the need for separate inserts, using a two-component adhesive with rapid curing properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If commercial inserts or onserts are used for force introduction into sandwich structures, then force transmission is achieved, but material consumption increases and process complexity increases due to manual insertion requirements
Solution Approach 1:
The patent extracts the separate insert component from the system and replaces it with a polymer composition injected directly into the sandwich structure. The mechanical connecting means is fixed directly in the polymer composition that is injected between the covering layers, eliminating the need for separate inserts or onserts and reducing material consumption.
Solution Approach 2:
The patent merges the insert function with the polymer composition by injecting the polymer directly into the sandwich structure and fixing the mechanical connecting means within it. This combines what were previously separate components (insert + adhesive) into a single integrated solution, reducing both material consumption and process steps.
2Force
If commercial inserts or onserts are used for force introduction, then force transmission is achieved, but process costs increase and reliability decreases due to manual insertion requirements
Solution Approach 1:
The patent replaces the manual mechanical insertion process with an automated injection process. The polymer composition is injected between the covering layers using injection technology, and the mechanical connecting means is fixed directly in the polymer composition, enabling automation and reducing process costs while improving reliability.
3Force
If standardized connecting means are used, then force introduction is achieved, but product design flexibility is limited
Solution Approach 1:
The patent applies local quality by allowing the polymer composition to be injected at specific locations and configured to match the exact requirements of each application. The mechanical connecting means can be fixed directly in the polymer composition at any position between the covering layers, enabling customized force introduction points and configurations rather than being constrained by standardized connecting means.
4Force
If force introduction points are concentrated, then connection is achieved, but loading capacity is limited due to inability to dissipate forces optimally
Solution Approach 1:
The patent transitions from pointwise force introduction to area-based force distribution by injecting the polymer composition between the covering layers at the desired location. This allows forces to be dissipated over a larger area within the intermediate layer rather than being concentrated at a single point, optimizing force distribution and increasing loading capacity.
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
This solution enhances force introduction and distribution, reduces material consumption and interface risks, and improves screwing resistance, while enabling automated and flexible force application, thus addressing the limitations of traditional methods.
Implementation Method 1
an in particular injected and preferably crosslinked polymer composition is arranged to form an insert in the intermediate layer
Implementation Method 2
a mechanical connecting means protruding through and from the first covering layer and/or the second covering layer is fixed directly in the polymer composition
Data Source
AI summary
A sandwich component comprising: (i) a first main surface with a first cover layer and a second main surface with a second cover layer, the first cover layer and/or second cover layer having an opening, weakening, or marking in a lateral region and/or is provided with the same, (ii) at least one intermediate layer positioned between the first and second cover layers, and (iii) a polymer composition which is arranged between the first and the second cover layers substantially within the intermediate layer and/or in the region of the opening, weakening, or marking. A mechanical connection mechanism is fixed, or can be fixed, directly in the polymer composition through the first cover layer and/or the second cover layer and/or in the lateral region in the region of the opening, weakening, or marking so as to pass through the first cover layer and/or the second cover layer and/or the lateral region.