Thermoplastic Panel Structure with Protruding Core for Reliable Fusion

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Solution Overview

Problem

The existing sandwich panel structures face adhesion failures between faceplates and core members when using adhesive agents, leading to reduced mechanical strength and increased weight, especially when bolts are used for reinforcement, and the manufacturing process becomes complex, particularly with fiber-reinforced resin materials.

Innovation Solution

A panel structure comprising a thermoplastic sheet-shaped core member with protruding portions and a thermoplastic faceplate, where a fusing portion is selectively formed between the faceplate and the core member to enhance the joining reliability without the need for bolts, using methods like heat fusion, ultrasonic vibration, or electromagnetic induction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If adhesive agents are used to join faceplates and core member, then joining process is simple, but adhesion failure occurs and joining reliability decreases

Engineering Contradiction:

Improvejoining process simplicityVSAvoidjoining reliability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent replaces the chemical bonding mechanism of adhesive agents with a mechanical interlocking mechanism. The protruding portions on the core member insert into recesses on the faceplate, creating a mechanical connection that eliminates adhesion failure while maintaining manufacturing simplicity. This substitution of bonding mechanism directly resolves the contradiction between ease of manufacture and joining reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If bolts are used to increase adhesion strength, then joining reliability improves, but mechanical strength decreases and weight increases

Engineering Contradiction:

Improveadhesion reliabilityVSAvoidmechanical strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent replaces the bolt connection system with an integrated mechanical interlocking system formed directly in the sandwich panel structure. The protruding portions and recesses create a unified structural connection that maintains the integrity of the fiber-reinforced resin material, avoiding the strength reduction and weight increase associated with bolt holes and fasteners.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The joining mechanism is merged into the core member and faceplate themselves through the protruding portions and recesses. This integration eliminates separate joining members (bolts) and combines the structural components with the joining function, preserving mechanical strength while achieving reliable connection.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If bolts are used to improve adhesion, then joining strength increases, but weight increases

Engineering Contradiction:

Improveadhesion strengthVSAvoidpanel weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates the separate joining members (bolts) from the sandwich panel structure. The joining function is achieved through the integrated protruding portions and recesses, removing the additional weight of fasteners while maintaining adequate connection strength for the application.

Inventive Principle:

Principle #2Taking out (Extraction)

4Reliability

If bolts are used for joining, then adhesion reliability improves, but manufacturing process becomes complicated

Engineering Contradiction:

Improveadhesion reliabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The joining mechanism is merged into the core member and faceplate manufacturing process itself. The protruding portions and recesses are formed as integral features during material processing, eliminating separate joining steps and reducing manufacturing complexity while ensuring reliable connection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protruding portions and recesses are prepared in advance during the manufacturing of the core member and faceplate, before final assembly. This preliminary formation of joining features simplifies the overall manufacturing process by integrating the joining preparation into the component fabrication steps rather than requiring separate operations.

Inventive Principle:

Principle #10Preliminary action

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

This configuration improves the reliability of the joining process between the faceplate and the core member, eliminates the need for additional joining members, and simplifies the manufacturing process while maintaining mechanical integrity.