Three-Layer Thermoplastic Composite Panels for Load-Bearing Edge Connections
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Solution Overview
Problem
Composite panels made of plastic materials are prone to delamination under high forces and are difficult to connect to other structures, especially when fibre-reinforced, lacking the strength and rigidity needed for robust applications.
Innovation Solution
A composite panel design featuring three thermoplastic polymer layers with an elongated element extending beyond the middle layer, chemically adhered or cross-linked, and reinforced with fibre-reinforced layers, allowing for strong connections through snap-fit joints or hinges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite panels are made with multiple layers of plastic materials, then weight is reduced, but strength and resistance to delamination deteriorate under high forces
Solution Approach 1:
The patent employs a multi-layer composite structure combining thermoplastic polymer layers with fibre-reinforced layers (glass fibres, carbon fibres, aramid fibres, or basalt fibres). This composite material approach maintains the weight advantage of plastic materials while significantly enhancing strength and delamination resistance through the synergistic combination of different materials with complementary properties.
Solution Approach 2:
The invention introduces elongated elements (profiles, inserts, or reinforcement elements) at specific locations where high forces are expected, such as edges and corners of the composite panel. These localized reinforcement elements provide additional strength and rigidity precisely where needed, without adding unnecessary weight to the entire panel structure.
2Strength
If composite panels use fibre-reinforced plastic materials, then strength is improved, but ease of connection to other structures deteriorates
Solution Approach 1:
The patent integrates connection elements directly into the composite panel structure during manufacturing, rather than adding them separately afterward. The elongated elements are incorporated as integral parts of the panel, with connection features (such as recesses, protrusions, or threaded holes) built-in at specific locations. This segmentation approach allows the panel to maintain its structural integrity while providing dedicated connection points that are easy to use.
3Strength
If composite panels are designed for high strength and rigidity, then resistance to tensile stress and vibrations is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functions into the elongated elements: structural reinforcement, edge protection, and connection facilitation. These single integrated elements simultaneously provide mechanical strength, rigidity, vibration resistance, and connection capabilities, eliminating the need for separate components for each function and thereby reducing overall device complexity.
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 design provides enhanced tensile strength, resistance to shocks and vibrations, and facilitates easy and reliable connection to other structures, suitable for applications like containers, transport vehicles, and landing platforms.
Implementation Method 1
the first boundary surface (bs1) is chemically adhered or glued or chemically cross-linked to the second boundary surface (bs2), and wherein the third boundary surface (bs3) is chemically adhered or glued or chemically cross-linked to the fourth boundary surface (bs4)
Implementation Method 2
the first portion (g1) of the elongated element (g) has a fifth boundary surface (bs5) that is chemically adhered or glued or chemically cross-linked to the first boundary surface (bs1) of the first thermoplastic polymer layer (a1), and has a sixth boundary surface (bs6) that is chemically adhered or glued or chemically cross-linked to the fourth boundary surface (bs4) of the third thermoplastic polymer layer (a3)
Data Source
Figure 1A~1C
Figure 2~3
Figure 4~5
AI summary
A composite panel comprising an edge profile (g) with load bearing capacity, the composite panel comprising: a first (a1), a second (b), and a third (a3) thermoplastic polymer layer stacked on top of each other, and pairwise chemically adhered or glued or chemically cross-linked to each other; the first and third layer (a1, a3) extending further than the second layer (b); the composite panel further comprising an elongated element (g) having a first portion (g1) situated between the first and third layer (a1, a3), and a second portion (g2) situated outside of the first and third layer (a1, a3); the first portion (g1) being chemically adhered or glued or chemically cross-linked to the first (a1) and third (a3) thermoplastic polymer layer.