Shaped Sandwich Panel Forming via Perforated Layer Pressurization
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Solution Overview
Problem
Existing methods for manufacturing shaped sandwich panels often deform the honeycomb core during shaping, particularly when complex geometries are required, due to the pressure differential bonding processes used.
Innovation Solution
A process involving a perforated second layer that allows pressurizing fluid to enter the panel, pushing the first layer and core against a die without excessive deformation, using a pressure vessel connected to the first layer, and diffusion bonding or brazing the layers together, allowing for shaping without moving the dies or supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a pressure differential bonding process is used to manufacture sandwich panels, then the layered metallic materials can be bonded together, but the honeycomb core may be crushed or deformed during subsequent shaping
Solution Approach 1:
The patent divides the panel into three distinct layers: a solid first layer, a perforated second layer, and a hollow core layer. This segmentation allows the solid first layer to bear the shaping forces while the hollow core layer maintains its structural integrity and is protected from direct deformation during the shaping process.
Solution Approach 2:
The patent applies different properties to different layers: the first layer is made solid to provide structural support during shaping, the second layer is made perforated to allow fluid passage, and the core layer is made hollow to reduce weight while maintaining strength. This local differentiation of material properties enables the solid first layer to protect the hollow core from deformation during shaping.
2Shape
If significant deformation is required to achieve complex geometries, then the panel can be shaped to complex curves, but the honeycomb core is crushed or deformed
Solution Approach 1:
The patent segments the panel into a solid first layer and a hollow core layer, allowing the solid layer to undergo significant deformation to achieve complex geometries while the hollow core remains protected and maintains its structural integrity throughout the shaping process.
Solution Approach 2:
The solid first layer acts as an intermediary between the shaping forces and the hollow core layer. It absorbs the deformation stresses and transfers minimal force to the core, enabling complex shaping while protecting the core from crushing or deformation.
3Ease of manufacture
If a perforated second layer is used to allow pressurizing fluid entry, then the first layer can be pushed to the desired shape, but the structure becomes more complex
Solution Approach 1:
The patent uses pressurized fluid (pneumatics) to inflate the hollow core layer, which in turn pushes the solid first layer against the die to achieve the desired shape. This pneumatic mechanism provides effective shaping capability while avoiding the need for complex mechanical pressing systems.
Solution Approach 2:
The second layer is made perforated (porous) to allow pressurized fluid to pass through and enter the hollow core layer. This porous structure enables fluid flow necessary for shaping while adding minimal structural complexity compared to a solid 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
Enables the formation of sandwich panels with complex geometries while minimizing deformation of the honeycomb core, allowing for precise shaping without crushing or deforming the core layer, thus improving the manufacturing process for such panels.
Implementation Method 1
a pressure differential may be applied across the layered metallic materials to simultaneously compress and bond the materials together
Implementation Method 2
heating within a process chamber. The process chamber may be a vacuum furnace or an inert gas furnace
Implementation Method 3
Bonding material is typically arranged between adjacent layers of the metallic materials, which material bonds the layers together; e.g., by liquid interface diffusion or brazing
Data Source
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AI summary
A process for manufacturing a shaped sandwich panel includes arranging a sandwich panel (66) adjacent a die (74). The sandwich panel (66) includes a core layer (26') arranged between and connected to a first layer (22') and a second layer (24'). The core layer (26') includes a plurality of apertures (38) that extend through the core layer (26') to the first layer (22'). The first layer (22') engages the die (74). Fluid within the apertures is pressurized to a pressure adequate to at least partially form the sandwich panel (66) to a geometry of the die (74).