Composite Plastic Core Member With Open-Pore Honeycomb Structure
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Solution Overview
Problem
Existing core materials in lightweight construction, such as honeycomb structures, face limitations in achieving a low density while maintaining a high bulk modulus-to-density ratio and mechanical properties, particularly when reducing cell size.
Innovation Solution
A method for producing core bodies using an open-pore support, where the carrier material is woven or nonwoven fabric, impregnated with adhesive strips and expanded into a honeycomb shape, ensuring air permeability through open-pored cell walls, and coated with a synthetic resin after formation, allowing for a unique combination of low density and high bulk modulus-to-density ratio.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cell size is reduced to improve mechanical properties, then bulk modulus to density ratio is improved, but density increases
Solution Approach 1:
The patent utilizes open-pore supports with controlled porosity to achieve low density while maintaining structural integrity. The porous structure allows the material to maintain high bulk modulus to density ratio without significantly increasing density, resolving the contradiction between mechanical properties and density.
Solution Approach 2:
The patent employs composite materials combining open-pore supports with synthetic resin coatings. This composite structure enables the material to achieve enhanced mechanical properties through the combination of different material characteristics, maintaining low density while improving bulk modulus to density ratio.
2Strength
If cell size is reduced to improve mechanical properties, then structural strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the open-pore support structure before final assembly. The support structure is prepared in advance with the desired cell geometry, and then coated with synthetic resin to achieve the final product. This approach simplifies manufacturing by separating the structural formation from the material application steps.
Solution Approach 2:
The patent utilizes parameter changes by adjusting the cell size and porosity of the open-pore support to optimize mechanical properties. By varying these parameters within specific ranges, the patent achieves improved structural strength without proportionally increasing manufacturing complexity.
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 method achieves core bodies with densities as low as 26 kg/m³ and bulk modulus-to-density ratios exceeding 5.8 MPa/kg/m³, along with excellent dielectric properties and mechanical strength, suitable for aerospace applications.
Implementation Method 1
ensuring air permeability through open-pored cell walls
Data Source
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AI summary
Described are a core member having improved mechanical properties as well as a method for the production thereof and a core member produced according to said method.