Sandwich Panel with Non-Woven Polyester Core and Primer Adhesion
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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 a specific density and surface roughness, and an adhesive layer that satisfies certain linear expansion coefficients, enhancing adhesion and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sandwich panels use adhesive bonding between skin layer and core layer, then the panel structure is simple to manufacture, but the interlayer bonding force is weak and the panel easily peels off under external load or impact
Solution Approach 1:
The patent introduces a primer layer as an intermediary substance between the adhesive layer and the core layer. This primer layer serves as a mediator that enhances the bonding interface, allowing the adhesive to bond more effectively to the core layer surface, thereby preventing peeling while maintaining manufacturing simplicity
Solution Approach 2:
The patent modifies the surface properties of the core layer through primer treatment, changing the surface energy and chemical composition parameters. This parameter change enables better wetting and adhesion of the adhesive layer, transforming the weak bonding interface into a strong bonded structure
2Weight of moving object
If sandwich panels use foamed resin material in the core layer, then the weight lightening effect is increased, but the mechanical strength and elongation properties are insufficient
Solution Approach 1:
The patent uses a non-woven fabric core layer made from synthetic fibers (polyester, polypropylene, or polyacrylonitrile) instead of foamed resin. This composite material structure provides both lightweight properties and superior mechanical strength with good elongation, resolving the contradiction between weight reduction and strength maintenance
Solution Approach 2:
The non-woven fabric core layer has a porous structure that provides lightweight properties similar to foamed materials, while the interconnected fiber network maintains high mechanical strength and elongation capabilities, avoiding the brittleness of foamed resin
3Strength
If sandwich panels use general resin, composite or balsa wood material in the core layer, then the mechanical strength is increased, but the weight lightening effect is reduced
Solution Approach 1:
The patent optimizes the density and fiber composition parameters of the non-woven fabric core layer to achieve the highest possible strength-to-weight ratio. By controlling fiber arrangement and density, the panel achieves mechanical strength comparable to heavier materials while maintaining significant weight reduction
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 various industries, including home appliances, construction, and transportation, while maintaining low moisture absorption and maintaining mechanical strength 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.