Self-Integrated Sandwich Panel Design for Improved Strength, Reduced Failure Rate

Executive Summary
The invention is a novel concept for eliminating the failure point of current sandwich panels, producing a structure that provides greater strength without an increase in weight.

Background
Composite sandwich structures with a corrugated inner core make lightweight panels for applications ranging from ship hulls to armor. Currently, such panels are fabricated by stitching the inner corrugated material to flat facing sheets. While this method produces lightweight panels, the stitching is often a failure point, limiting the panels’ overall strength.

Invention Description
This invention introduces geometry for a trussed core panel that can be fabricated as a single unit, without any stitching. The fully self-integrated panel design eliminates the failure point of existing alternatives, allowing the improved panels to provide greater strength while remaining lightweight. Further, inserts can be placed between the corrugations to further improve impact-, thermal and electrical resistance.

Advantages
This technology:

• Uses a novel concept for reinforcing the sandwich panel with a corrugated inner core, eliminating the primary failure mode of pre-existing technologies and also enhancing structural, impact and blast protection
• Enables customization with the addition of various inserts, offering added protection for variety of applications such as enhanced ballistic, thermal or electrical resistance

Potential Applications
This invention can be used to enhance protection in a variety of ways, such as in:

• Lightweight armor
• Strong, lightweight structures
• Customized insulation