Composite Core Structure Using Thermal Compression Layers
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Solution Overview
Problem
Residual thermal stresses during the curing process of composite structures with foam or honeycomb cores lead to cracks and delamination, reducing the service life and increasing rejection rates.
Innovation Solution
A composite structure design with asymmetrically oriented compression layers on the skin, featuring different thermal expansion coefficients, which induces compressive forces on the core material upon cooling, mitigating tensile stresses and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional symmetric composite structure is used, then manufacturing process is simple, but thermal stress causes cracks and delamination
Solution Approach 1:
The patent applies asymmetry by positioning compression layers at different locations on the skin surface (e.g., leading edge vs trailing edge, or different circumferential positions) rather than symmetrically. This asymmetric arrangement creates differential thermal contraction that generates compressive forces on the core material during cooling, counteracting tensile thermal stresses and preventing cracks and delamination while maintaining manufacturing simplicity
Solution Approach 2:
The patent changes the spatial parameter of compression layer positioning from symmetric to asymmetric arrangements. By modifying the position parameters (angular position, radial position, or circumferential distribution) of compression layers, the structure generates beneficial compressive thermal stresses that improve reliability without significantly complicating the manufacturing process
2Reliability
If compression layers are added to mitigate thermal stress, then structural integrity improves, but device complexity increases
Solution Approach 1:
The patent applies local quality by placing compression layers only at specific critical locations on the skin (such as leading edge, trailing edge, or specific circumferential positions) rather than uniformly across the entire structure. This localized approach generates the necessary compressive thermal stresses to improve structural integrity while minimizing the additional complexity compared to a uniform symmetric design
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
The design effectively reduces thermal stress-induced failures by applying compressive forces to the core, thereby improving structural durability and reducing defects.
Implementation Method 1
A composite structure design with asymmetrically oriented compression layers on the skin, featuring different thermal expansion coefficients, which induces compressive forces on the core material upon cooling
Data Source
Figure 1~2
Figure 3~6
AI summary
Method of manufacturing a composite component (10) comprises forming a core (22), surrounding the circumference of the core with a first layer of fabric (24), applying a second layer of fabric (26) having a different coefficient of thermal expansion from the first layer such that the second layer extends around at least a portion of the circumference of the core and curing the component such that the second layer imparts a compressive or tensile force on the core.