Composite Core Tube Geometry for Stronger Bonded Honeycomb
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Solution Overview
Problem
Conventional methods for manufacturing composite honeycomb cores are labor-intensive and result in products that are not optimal for various structural implementations, making them expensive and inefficient.
Innovation Solution
The method involves arranging multiple elongate tubes with curved sides in a two-dimensional array to form non-traditional geometries, using a mandrel wrapping process with controlled pressure and orientation of composite material, which includes reinforcement fibers in a polymeric matrix, to create a composite core with increased stiffness and strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manual pressing methods are used to create corrugated patterns in composite layers, then the honeycomb core can be manufactured, but the process becomes labor intensive and expensive
Solution Approach 1:
The composite core is divided into multiple individual tubes arranged in a two-dimensional array, with each tube being a separate structural element that can be independently formed and then assembled into the final core structure
Solution Approach 2:
Tubes are pre-formed with the desired corrugated geometry using mandrels before being assembled into the final honeycomb core structure, allowing for more efficient manufacturing of individual components that are then systematically assembled
2Adaptability or versatility
If conventional manufacturing methods are used, then honeycomb core can be produced, but the geometry is not optimal for various structural implementations
Solution Approach 1:
The patent employs non-traditional tube geometries including asymmetric corrugation patterns, varying crest and valley configurations, and non-uniform cross-sectional shapes that deviate from conventional symmetric hexagonal patterns to optimize structural performance for specific applications
Solution Approach 2:
The tubes feature curved corrugation profiles with rounded crests and valleys rather than sharp angular transitions, creating smooth continuous curves that improve structural properties while maintaining manufacturability through controlled forming processes
3Strength
If traditional hexagonal or regular polygon geometries are used, then manufacturing is simplified, but surface area contact and adhesive bond length are reduced
Solution Approach 1:
The tube geometries extend traditional two-dimensional hexagonal patterns into three-dimensional complex forms with varying cross-sections, multi-level corrugations, and spatial configurations that increase surface area and contact opportunities without sacrificing assembly feasibility
Solution Approach 2:
Different sections of the tubes feature locally optimized corrugation patterns with varying amplitude, wavelength, and curvature radii to maximize surface area contact in specific regions while maintaining overall structural integrity and manufacturability
Data Source
AI summary
A composite core with non-traditional geometries includes multiple elongate tubes arranged in a two-dimensional array. Each tube is made of a composite material. Each tube includes multiple curved sides. Each curved side inwardly curves toward a longitudinal axis passing through a geometric center of the tube to form a valley on an outer surface of the tube. An end of a first curved side connects to an end of a second curved side to form a crest on the outer surface of the tube. At least one crest formed on an outer surface of a first tube in the two-dimensional array contacts at least one valley formed on an outer surface of an adjacent second tube in the two-dimensional array.