Efficient sub-structures
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Solution Overview
Problem
Current honeycomb-like structures for aircraft and other applications are uniform and cannot be varied in cell size, shape, or material, limiting their ability to meet specific engineering requirements for load and stress conditions, and are undesirably heavy due to design limitations.
Innovation Solution
The use of additive manufacturing to create honeycomb-like structures with varying cell sizes, shapes, and materials, allowing for tailored strength and weight distribution by forming seamless resin-infused fiber composite materials with different cell types and wall thicknesses, and incorporating lightening holes to reduce weight without compromising stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform honeycomb structures are used due to manufacturing limitations, then ease of manufacture is improved, but adaptability to different load and stress conditions deteriorates
Solution Approach 1:
The patent applies local quality by varying the honeycomb cell structure in different regions of the same component. Different zones have different cell sizes, shapes, wall thicknesses, or material compositions tailored to specific load and stress conditions in those regions, while still being manufactured as a single seamless component using additive manufacturing.
2Device complexity
If uniform honeycomb structures are used, then device complexity is reduced, but strength distribution under varying load conditions deteriorates
Solution Approach 1:
The patent implements local quality by creating region-specific honeycomb variations within the component. Areas experiencing higher loads have denser or thicker-walled cells, while lower-stress areas have lighter structures, optimizing overall strength distribution without requiring multiple assembled components.
3Ease of manufacture
If uniform honeycomb structures are used, then manufacturing simplicity is improved, but weight efficiency deteriorates
Solution Approach 1:
The patent applies local quality by varying honeycomb cell density and wall thickness across different regions of the component. High-stress areas receive denser reinforcement while low-stress areas maintain lighter structures, achieving optimal weight efficiency for the specific application without requiring assembly of multiple uniform components.
4Adaptability or versatility
If seamless resin-infused fiber composite materials are used with additive manufacturing, then adaptability to specific engineering requirements is improved, but manufacturing complexity deteriorates
Solution Approach 1:
The patent merges multiple functions and variations into a single seamless component manufactured using additive manufacturing with resin-infused fiber composites. This combines the advantages of customized local structures with the benefits of monolithic construction, eliminating the need for assembly while achieving complex geometries and material property variations.
Data Source
AI summary
A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of honeycomb-like cells, and a second plurality of honeycomb-like cells, different than the first plurality of honeycomb-like cells.