Twisted Spacer Structure for Stable Sandwich Construction

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Solution Overview

Problem

Existing sandwich constructions with deep-drawn spacing elements face issues of material instability, reduced thickness, and limited mechanical stability due to material elongation, while tab-based constructions offer limited load-bearing capacity and require multiple fixing points.

Innovation Solution

A spacer structure with distorted bearing surfaces and spacing elements formed by bending, maintaining material thickness and enhancing mechanical stability through twisted connections, allowing for a mono-material construction with simplified production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If spacing elements are produced by deep drawing, then the spacing elements can be formed with high precision, but the material thickness is reduced and mechanical stability deteriorates

Engineering Contradiction:

Improvespacing element formation precisionVSAvoidmechanical stability

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent changes the forming method from deep drawing to bending, which fundamentally alters the deformation mechanism. Bending produces lower stresses and prevents material thinning, thereby maintaining material thickness and mechanical stability while still achieving precise spacing element formation

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the deep drawing mechanical process with a bending process. This substitution eliminates the material elongation and thickness reduction inherent in deep drawing, while the bending process maintains manufacturing precision through controlled deformation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Stability of the object's composition

If spacing elements are configured as tabs, then material thickness is maintained, but load-bearing capacity is limited and fixing points increase

Engineering Contradiction:

Improvematerial thickness stabilityVSAvoidload-bearing capacity

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The patent introduces a third dimension by creating distorted, three-dimensional spacing elements through bending. The distortion creates a spatial configuration that provides both the thickness stability of tabs and the enhanced load-bearing capacity of bridgelike structures, while reducing the number of fixing points required

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If special materials with high tensile strength are used, then strength is improved, but suitability for deep drawing deteriorates

Engineering Contradiction:

Improvetensile strengthVSAvoiddeep drawing suitability

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces the deep drawing process with bending, which is compatible with high tensile strength materials. Bending produces lower stresses that do not exceed the elastic limit of strong materials, unlike deep drawing which requires material elongation capability. This allows the use of special materials without compromising manufacturability

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Stability of the object's composition

If tabs are bent back for safety, then material integrity is maintained, but load-bearing capability deteriorates under shear forces

Engineering Contradiction:

Improvematerial integrityVSAvoidload-bearing capability

Core Design Contradiction:

Stability of the object's compositionVSStrength

Solution Approach 1:

The patent creates distorted, three-dimensional spacing elements that extend beyond simple planar tab configurations. The distortion in the third dimension provides additional structural support and load paths, enabling the elements to maintain material integrity while significantly improving load-bearing capability under shear forces

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 spacer structure provides increased mechanical stability, reduced material thickness change, and efficient energy use, enabling a stable, cost-effective, and easily producible sandwich construction suitable for various applications.

Implementation Method 1

by a forming process of bending the bearing surfaces out of the first plane, the bearing surfaces are twisted in relation to the first plane

Methodology Applied

Scientific EffectBending: Deformation

Data Source

PatentUS12403517B2Spacer structure, sandwich construction with a spacer structure of this kind and method for producing a spacer structure of this kind

Publication Date: 2025.09.02 MATRIX MODULE GMBH

AI summary

A spacer structure for a sandwich construction, formed from a material web which is provided with a plurality of cuts and which has a material web plane as a first plane, wherein, by forming the material web, at least one support platform is formed in portions which is spaced at a distance from the first plane and is arranged in a second plane. Spacing elements run along a direction of extent (E) from the first plane into the second plane in the transition zone from the first plane into the second plane and thus the spacing elements space the first plane apart from the support platform, the spacing elements having a twist about the direction of extent thereof along the direction of extent thereof (E), the twist being formed by the shaping of the material web being performed as bending.