Viscoelastic Insert for Sandwich Panel Thickness Compensation
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Solution Overview
Problem
Existing methods for producing sandwich panels with inserts often result in pressure shadows and uneven features due to inserts being either too large or too small, leading to unreliable connections between the core structure and cover layers.
Innovation Solution
The method involves using an insert with two sections, where one section is cured and the other is a viscous expansion compound with adhesive properties, allowing it to adapt to the panel's thickness and ensure homogeneous characteristics, thereby preventing pressure shadows and ensuring reliable connections by integrating the insert with the cover layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insert is made too large to ensure sufficient connection area, then the connection reliability improves, but pressure shadows form in the surrounding region causing uneven features
Solution Approach 1:
The insert is divided into two functional sections: a first section (cured state) that provides structural support and connection reliability, and a second section (uncured viscous state) that flows to fill gaps and prevent pressure shadows. This segmentation allows each section to optimize its function without compromising the other.
Solution Approach 2:
The insert material undergoes a parameter change from uncured viscous state to cured solid state during the molding process. In the uncured state, the material is fluid and can flow to fill voids and prevent pressure shadows. After curing, it becomes solid and provides the necessary structural support and connection reliability.
2Manufacturing precision
If the insert is made too small to avoid pressure shadows, then thickness uniformity improves, but connection reliability deteriorates
Solution Approach 1:
The insert is divided into two functional sections: a first section (cured state) that provides structural support and connection reliability, and a second section (uncured viscous state) that flows to fill gaps and prevent pressure shadows. This segmentation allows each section to optimize its function without compromising the other.
Solution Approach 2:
The insert material undergoes a parameter change from uncured viscous state to cured solid state during the molding process. In the uncured state, the material is fluid and can flow to fill voids and prevent pressure shadows. After curing, it becomes solid and provides the necessary structural support and connection reliability.
3Reliability
If additional adhesives are used to bond the insert to cover layers, then connection reliability improves, but device complexity increases
Solution Approach 1:
The bonding function is merged into the insert material itself. The uncured section of the insert acts as both a flowable filler to prevent pressure shadows and an adhesive to bond the insert to the cover layers, eliminating the need for separate adhesive materials and application steps.
Solution Approach 2:
The insert material performs multiple functions on its own: it provides structural support, prevents pressure shadows through flow, and bonds to the cover layers through its adhesive properties. This self-service capability eliminates the need for additional adhesive materials and simplifies the overall process.
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 approach prevents pressure shadows and uneven features, ensures reliable core structure connections, and eliminates the need for additional adhesives by using the expansion compound's adhesive properties to bond the insert to the cover layers.
Implementation Method 1
a viscous expansion compound with adhesive properties, which has solidified during the pressing of the sandwich panel, by which an difference between its extension and the cover layer distance is compensated for
Implementation Method 2
a viscous expansion compound with adhesive properties
Data Source
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AI summary
Disclosed are a sandwich panel with at least one insert for forming a local reinforcement, which insert is smaller than a cover layer distance of the sandwich panel, wherein a difference between its extension and the cover layer distance from a previously viscous expansion compound with adhesive properties, which expansion compound has solidified during the pressing of the sandwich panel, is compensated for; a sandwich panel with at least one previously elastic insert whose original extension as a result of deformation during pressing of the sandwich panel is reduced; as well as a method for producing such sandwich panels.