Sandwich Structure Insert Finishing to Prevent Insert Pull
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Solution Overview
Problem
Existing sandwich structures with embedded inserts often experience 'insert pull,' where the cover layer is drawn toward the core, leading to surface indentations and deformation, especially when screws are tightened, resulting in costly reworking and weight increases when using rigid fillers to prevent this issue.
Innovation Solution
A method for producing sandwich structures with embedded connecting elements, where the insert is machined flush with or protrudes from the cover layer, preventing relative movement and insert pull when screws are tightened, and using a compensating element or grinding to achieve this flush alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive layers are used to connect foam halves, then bonding is achieved, but production time increases and production costs rise
Solution Approach 1:
The patent extracts the adhesive layer from the bonding process and replaces it with mechanical connection elements (connecting elements with threads) that directly engage the foam halves. This eliminates the time-consuming adhesive application and curing process while maintaining bonding strength through threaded mechanical fastening.
Solution Approach 2:
The patent introduces connecting elements as intermediary components between the foam halves. These connecting elements feature threads that engage with threaded bores in the foam halves, providing a mechanical mediation that achieves strong bonding without requiring adhesive layers, thereby reducing production time and costs.
2Strength
If adhesive layers are used to connect foam halves, then bonding is achieved, but production costs increase
Solution Approach 1:
The patent removes adhesive materials from the construction process and replaces them with reusable connecting elements. This eliminates the cost of adhesive materials and the labor associated with adhesive application and curing, reducing overall production costs while maintaining bonding strength through mechanical threading.
Solution Approach 2:
The connecting elements serve as cost-effective intermediaries that provide strong bonding without the need for expensive adhesive materials. The threaded mechanical connection allows for simple, fast assembly with standard tools, reducing both material costs and labor costs compared to adhesive-based bonding.
3Stability of the object's composition
If connecting elements are inserted before foam expansion, then embedding is achieved, but precise positioning becomes difficult
Solution Approach 1:
The patent applies preliminary action by inserting the connecting elements into the foam material before the foam fully expands. The connecting elements are positioned in advance within the mold cavity, and as the foam expands around them, the elements become embedded at precise, predetermined locations. This preliminary positioning ensures accurate final placement without requiring complex positioning mechanisms.
Solution Approach 2:
The connecting elements are nested within the foam material during the expansion process. The foam expands around and encapsulates the connecting elements, which are already positioned in the mold. This nesting approach allows the foam to naturally hold the connecting elements in their correct positions as it cures, achieving precise embedding without additional positioning steps.
Data Source
Figure 1a~1d
Figure 2a~2e
Figure 3
AI summary
The invention relates to a sandwich structure (1) having an embedded connecting element (6) and to a method for producing same. The sandwich structure (1) according to the invention, having two cover layers (2, 3) and a core (4) arranged therebetween, has at least one connecting element (6) for connection to further components, wherein the connecting element (6) comprises an insert (7) which is embedded into the sandwich structure (1) at a cover layer (2) and the embedding depth of which is less than the thickness of the core (4). Here, the connecting element (6) is finished flush with the outer side of the cover layer (2) via which the connecting element (6) is embedded, or protrudes from the cover layer (2). The method according to the invention for producing such a sandwich structure (1) comprises the following steps: a) producing a blind hole (5) starting from a cover layer (2) of the sandwich structure (1); b) introducing the connecting element (6) into the blind hole (5) and fastening the connecting element (6) therein; and c) finishing the connecting element (6) such that it is flush with the cover layer (2) or protrudes by a predetermined height from the cover layer (2).