Open-Area Core Sandwich Tool for High-Gloss Sealed Edges
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Solution Overview
Problem
Existing sandwich composite structures face challenges in achieving high gloss surfaces, moisture resistance, and consistent edge sealing, which complicates manufacturing and limits their utility in vehicles due to additional processing steps and difficulty in attaching components.
Innovation Solution
A manufacturing tool that forms a sandwich composite structure with a high gloss surface and sealed edges in a single step, using adhesive layers to adhere a surface sheet and structural skin to an open area core, while incorporating a sealing and cutting edge to prevent moisture infiltration and trim excess material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional sandwich structures are used to provide strength and reduced weight, then weight savings and structural strength are achieved, but the ability to obtain a vehicle exterior quality high gloss surface remains a challenge
Solution Approach 1:
The patent incorporates a high-gloss surface layer and sealing edge as integral parts of the sandwich structure during the initial manufacturing process. The sealing edge is formed simultaneously with the core and surface layers, preventing moisture infiltration from the outset. This preliminary action eliminates the need for subsequent surface treatment or edge sealing operations that would be required in conventional approaches.
Solution Approach 2:
The patent merges multiple functions into a single integrated manufacturing step: forming the core structure, creating the high-gloss surface, and sealing the edges all occur simultaneously in one molding process. This consolidation resolves the contradiction by achieving both structural integrity and surface quality without requiring separate processing steps.
2Manufacturing precision
If additional outer layers are applied to provide a high gloss outermost layer, then surface gloss quality is improved, but cost and complexity of production increase
Solution Approach 1:
The patent combines the high-gloss surface layer and sealing edge into the same molding cycle as the core structure. This merging of functions eliminates the need for separate application steps for surface layers and edge sealing, thereby reducing production complexity while maintaining high gloss quality.
Solution Approach 2:
The high-gloss surface and sealing features are created during the initial molding process rather than as subsequent additions. This preliminary formation eliminates the need for post-manufacturing operations, reducing both complexity and cost while achieving the desired surface quality.
3Reliability
If additional processing steps are used to seal edges and trim excess material, then moisture resistance and edge quality are improved, but manufacturing time and cost increase
Solution Approach 1:
The sealing edge is formed as an integral part of the sandwich structure during the initial molding process. This preliminary formation of the sealing edge prevents moisture infiltration from the outset and eliminates the need for subsequent edge sealing operations, thereby maintaining reliability while improving productivity.
Solution Approach 2:
The patent merges edge sealing, trimming, and surface formation into a single molding operation. This consolidation achieves moisture-resistant sealed edges and proper trimming simultaneously with the core structure formation, eliminating multiple sequential processing steps and improving manufacturing throughput.
4Reliability
If skilled craftsmen or multiple expensive manufacturing tools are used to seal and trim edges, then edge quality and moisture resistance are improved, but manufacturing cost and time increase
Solution Approach 1:
The sealing edge and trimmed edges are formed as integral features during the initial molding process. This preliminary formation eliminates the need for subsequent manual or machine-based edge sealing and trimming operations, reducing both device complexity and manufacturing cost while maintaining reliable edge sealing quality.
Solution Approach 2:
The patent combines edge sealing, trimming, and surface formation into a single integrated molding operation. This merging of functions eliminates the need for separate skilled labor or additional expensive tools, reducing device complexity while achieving reliable edge sealing and proper trimming.
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 tool produces composite structures with high gloss surfaces and sealed edges, enabling mass production and readiness for additional attachments, enhancing manufacturing throughput and reducing delamination risks.
Implementation Method 1
A first adhesive layer is intermediately positioned between the high gloss surface sheet and the open area core and a second adhesive layer is intermediately positioned between the structural skin and the open area core
Data Source
AI summary
A tool for manufacturing a sandwich composite material component is provided that includes a lower tool having a surface configured to receive materials for forming the sandwich composite material component. An upper tool is also provided that has a sealing edge and a cutting edge. The upper tool and the lower tool are configured to be separated to an open position and to be brought together to a closed position, the upper tool and the lower tool define a cavity when in the closed position. A process for forming a sandwich composite material component is also provided.