Sandwich Lightweight Panel Foaming Without Steam Equipment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing planar structural elements in sandwich lightweight construction require steam and are not cost-effective for producing components with high stiffness and low weight.
Innovation Solution
A method using expandable particle foams like EPS, EPE, or EPP, partially foamed and then fully foamed within a tool to bond with a film-like substrate, eliminating the need for steam and ensuring a strong, lightweight, and high-quality surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If steam is used to foam particles to final consistency, then the particles can be fully expanded and cured, but the process becomes more complex and costly with mandatory steam equipment
Solution Approach 1:
The patent extracts the steam generation and injection equipment from the foaming process, replacing it with a simpler heating system that directly heats air which then contacts the particles. This eliminates the complex steam equipment while achieving the same foaming result through a more straightforward heating approach.
Solution Approach 2:
The patent replaces the mechanical steam injection system with a thermal field-based approach using heated air. Instead of injecting steam mechanically, the system uses hot air circulation to transfer thermal energy to the particles, simplifying the equipment while maintaining foaming effectiveness.
2Ease of manufacture
If polyurethane two-component foams are used, then the process follows established methods, but the cost-effectiveness decreases and the process becomes less adaptable
Solution Approach 1:
The patent changes the material parameter from polyurethane two-component foam to expandable particle foam (EPS, EPE, or EPP). This material substitution provides greater adaptability in terms of density control, expansion ratios, and application flexibility while maintaining ease of manufacture through established particle foam technology.
Solution Approach 2:
The patent uses composite material systems combining expandable particles with binding agents that activate during heating. This creates a versatile foam structure that can be tailored to different applications while using simpler, more cost-effective materials compared to polyurethane two-component systems.
3Productivity
If particles are fully foamed in one step, then the process is simpler, but the ability to control final consistency and bond with substrate is reduced
Solution Approach 1:
The patent segments the foaming process into two distinct stages: partial foaming before substrate contact and final foaming after substrate positioning. This segmentation allows precise control over particle expansion timing and degree, ensuring optimal bond formation with the substrate while achieving complete expansion, thereby balancing productivity with manufacturing precision.
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 produces a lightweight, high-stiffness component with a durable surface, suitable for outdoor applications, at a lower cost, using expandable particle foams that bond with a substrate to form a rigid and load-bearing composite.
Implementation Method 1
the particles expand to their maximum size or volume and essentially fuse or sinter together. The particle foam mass simultaneously bonds with the substrate.
Implementation Method 2
the particles are then subjected to a final foaming process to form a fully foamed particle foam. The particles expand to their maximum size or volume
Implementation Method 3
the tool is further heated. The invention also encompasses keeping the tool constantly at a constant temperature or at a temperature within a predetermined temperature range. The partially foamed particles are then subjected to a final foaming process
Data Source
Figure 1~2
Figure 3~5
Figure 6~8
AI summary
The invention relates, among other things, to a method for producing a planar component (10) in sandwich lightweight construction with a high-quality surface (26).