Sandwich Panel with Optimized Core Density and Surface Roughness
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Solution Overview
Problem
Conventional sandwich panels have insufficient weight-lightening and mechanical strength, poor elongation properties, and weak interlayer bonding, making them unsuitable for heavy cargo protection and prone to peeling under external loads or impacts.
Innovation Solution
A sandwich panel with a core layer of non-woven polyester-based fibers and a binder, having an apparent density of 0.5 to 0.8 g/cm³, and a skin layer laminated with an adhesive layer, where the surface roughness and coefficient of linear expansion are optimized to enhance adhesion and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a foamed resin material is used in the core layer to increase weight lightening, then the weight of the panel is reduced, but the mechanical strength and elongation are insufficient
Solution Approach 1:
The patent uses a composite core layer made of thermoplastic resin and inorganic filler (such as glass beads or hollow spheres) to achieve both weight reduction and maintained mechanical strength. This composite structure allows the panel to be lighter than traditional solid resin cores while preventing the strength and elongation deficiencies that occur with foamed materials.
2Ease of manufacture
If adhesive is applied between the skin layer and core layer to bond them, then the layers are joined, but the interlayer bonding force is weak and formability is poor
Solution Approach 1:
The patent changes the surface parameters of the core layer by controlling its roughness to a specific range (3.0-10.0 μm) and adjusting its moisture content (5-15%). These parameter changes improve adhesive wetting and bonding strength without requiring additional bonding agents, thereby enhancing both the bonding force and formability while maintaining ease of manufacture.
3Strength
If the core layer density is increased to improve flexural strength and tension stiffness, then the mechanical properties are enhanced, but the weight lightening effect is reduced
Solution Approach 1:
The patent optimizes the core layer density to a specific range (0.30-0.80 g/cm³) and controls the fiber orientation and distribution parameters. By adjusting these parameters, the panel achieves high flexural strength and tension stiffness while maintaining a density that provides significant weight lightening compared to traditional solid cores.
Solution Approach 2:
The use of composite materials consisting of thermoplastic resin combined with inorganic fillers (glass beads, hollow spheres) allows the core layer to achieve high mechanical properties at lower densities. The inorganic fillers provide structural reinforcement while the resin matrix binds them together, creating a lightweight yet strong core layer.
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 solution provides a sandwich panel with improved flexural strength, tensile strength, and resistance to peeling, suitable for structural applications in home appliances, construction, and transportation, while maintaining low moisture absorption and maintaining mechanical properties over time.
Implementation Method 1
an adhesive layer for bonding the core layer and the skin layer
Implementation Method 2
a core layer of non-woven fiber structure having a polyester-based fiber and a binder
Data Source
AI summary
The present invention relates to a sandwich panel and a method of manufacturing the same. The sandwich panel according to the present invention has high density and improved physical properties such as flexural strength, flexural modulus, bending strength and lightening weighting ratio and is suitable for use in various consumer products or industrial materials.