Project Details

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Modifications to Strengthen Skin-to-Core Attachment in Insulated Panels

Company: TMP Manufacturing Company, Inc.

Major(s):
Primary: ME
Secondary: IE

Non-Disclosure Agreement: NO

Intellectual Property: NO

Tafco manufactures insulated walk-in cooler and freezer panels that must perform reliably across a wide range of temperature cycles. This project will take place at our facility in Clearfield, Pennsylvania, located approximately 50 miles (about a one-hour drive) from State College. Under real-world and stress test conditions, the metal skins and foam insulating core expand and contract at different rates due to their unique material properties. Over time, these stresses can lead to separation or de-lamination of the panel skins, especially during repeated freeze–thaw cycling or high-load conditions. We are seeking innovative engineering solutions that strengthen the attachment between the metal skins and the foam core without requiring major changes to our current panel fabrication process. Students will explore both mechanical and material-based concepts to improve skin retention. Potential approaches include adding mechanical interlocks or fasteners, introducing geometric features that enhance bonding, adjusting adhesive surface preparation, or selectively reinforcing high-stress regions. The goal is not to rebuild the panel from scratch, but rather to identify practical, minimal-disruption design modifications that increase reliability and durability. Creativity is encouraged, provided that concepts integrate smoothly with Tafco’s existing panel design and production workflow. Engineering analysis and testing will play a key role as students evaluate how various design changes respond to extreme thermal cycling and the resulting differential expansion between materials. This may involve modeling stress distributions, assessing adhesive performance, and considering the effects of temperature-driven fatigue. Concepts should be supported by quantitative reasoning and clear evidence that they reduce delamination risk under realistic loading scenarios. By the end of the project, the students will deliver validated design recommendations (supported by analysis, prototypes, or small-scale testing as appropriate) that enhance panel performance while remaining compatible with Tafco’s established manufacturing methods.