3D Woven Composite Core Interlocked Cells
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Solution Overview
Problem
Conventional composite sandwich structures face limitations in strength due to the honeycomb core's resin-infused paper structure, which can be cumbersome and costly, especially in applications requiring lightweight and high-strength materials.
Innovation Solution
A method of three-dimensionally weaving composite fibers to form a pre-form with interlocked open cells, allowing for a composite core with enhanced strength and ease of transportation and storage, using a system comprising a three-dimensional composite fiber weaving machine and controlled fiber orientations and lengths to create nested geometry cross-sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional resin-infused paper honeycomb structure is used for core, then the structure provides basic strength, but the manufacturing process becomes cumbersome and cost increases
Solution Approach 1:
The patent applies composite materials by weaving composite fibers (such as carbon, graphite, glass fibers) in a polymeric matrix (such as epoxy, polyetheretherketone) to form the core structure. This replaces the conventional resin-infused paper honeycomb with a composite material construction that provides enhanced strength while simplifying the manufacturing process through direct weaving and curing operations.
2Strength
If conventional resin-infused paper honeycomb core is used, then basic structural requirements are met, but weight increases and strength-to-weight ratio decreases
Solution Approach 1:
The patent implements local quality by creating a three-dimensional woven pattern where fibers are strategically oriented in different directions (X, Y, Z axes) to provide targeted strength in specific regions. This localized fiber orientation optimizes the strength-to-weight ratio by placing material only where structurally necessary, rather than using a uniform heavy construction throughout the entire core.
3Strength
If three-dimensionally woven composite fiber pre-form is used, then strength and weight characteristics are improved, but new manufacturing process complexity is introduced
Solution Approach 1:
The patent applies segmentation by dividing the core into multiple interlocked open cells formed by the three-dimensional woven fiber structure. Each cell is defined by fibers woven in specific patterns along different axes, creating a modular cellular architecture. This segmentation approach simplifies the overall manufacturing by breaking down the complex three-dimensional structure into repeatable unit cells that can be systematically produced.
Data Source
AI summary
In the present disclosure, a method may include forming a three-dimensional composite fiber pre-form by three-dimensionally weaving a plurality of composite fibers. The composite fiber pre-form includes a plurality of open cells formed adjacent to and interlocked with each other, and a composite fiber forms at least a portion of a first side of a first open cell and at least a portion of a second side of a second open cell. The first open cell and the second open cell are adjacent to and interlocked with each other.