Composite Honeycomb Core Filament Winding
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Solution Overview
Problem
Conventional methods for manufacturing composite honeycomb cores are labor-intensive and result in suboptimal structures for various structural implementations, making them expensive and inefficient.
Innovation Solution
A composite core system comprising a plurality of tubes with fibers wound in a polymeric matrix, where adjacent tubes are adhesively bonded or infused, allowing for variable winding angles and configurations to optimize shear and compression strength, and using methods like vacuum-assisted resin transfer molding or resin film infusion to introduce resin.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual pressing of mandrels against composite layers is used to create corrugated patterns, then honeycomb core structure is formed, but the process becomes labor intensive and expensive
Solution Approach 1:
The patent replaces the manual mechanical pressing process with an automated filament winding system that uses a robotic arm to deposit fibers and resin onto rotating mandrels. This substitution of mechanical manual operations with automated manufacturing equipment directly addresses the labor-intensive nature of conventional methods while improving production efficiency.
Solution Approach 2:
The invention changes the manufacturing parameters by using continuous fiber reinforcement with controlled winding angles (±45 degrees) and automated resin impregnation, rather than manual layering. This parameter change enables consistent structural properties and higher production rates, resolving the contradiction between ease of manufacture and productivity.
2Ease of manufacture
If manual pressing process is used to create honeycomb core, then basic structure is achieved, but the structure is not optimal for various structural implementations
Solution Approach 1:
The patent implements local quality by varying the fiber winding angle along the length of each tube and between adjacent tubes. The winding angle is optimized locally to provide enhanced strength in specific directions, creating a non-uniform but structurally optimized configuration that surpasses the uniform manual pressing approach.
Solution Approach 2:
The invention uses composite materials consisting of continuous reinforcement fibers embedded in a polymer matrix, deposited through filament winding. This composite structure provides superior mechanical properties compared to manually pressed layers, achieving optimal structural strength while maintaining manufacturing efficiency.
3Productivity
If conventional manual manufacturing is used, then production cost is high, but structural optimization is limited
Solution Approach 1:
The filament winding system performs multiple functions: it deposits fibers, impregnates with resin, forms the corrugated pattern, and cures the structure in a single integrated process. This multi-functionality reduces the need for separate manufacturing steps, lowering overall system complexity despite the advanced technology used, while maintaining high productivity.
Solution Approach 2:
The mandrels are pre-configured with the desired honeycomb pattern geometry before the filament winding process begins. This preliminary preparation allows the automated system to simply follow the pre-determined path, reducing the complexity of real-time control while achieving structurally optimized cores at high production rates.
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 solution provides a cost-effective and structurally optimized composite core with improved mechanical properties, enabling the production of composite sandwich structures with tailored strength and reduced material usage.
Implementation Method 1
A composite core system comprising a plurality of tubes with fibers wound in a polymeric matrix, where adjacent tubes are adhesively bonded or infused
Implementation Method 2
using methods like vacuum-assisted resin transfer molding or resin film infusion to introduce resin
Data Source
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AI summary
A method of wrapping a plurality of mandrels (1201, 1503, 1603, 1405, 1701, 1901, 2505) with a composite material (1401, 1501, 2603, 1103, 1601) can include rotating each mandrel (1201, 1503, 1603, 1405, 1701, 1901, 2505) at a rotational speed; translating each mandrel (1201, 1503, 1603, 1405, 1701, 1901, 2505) at a translation speed; positioning each mandrel (1201, 1503, 1603, 1405, 1701, 1901, 2505) back to back such that an aft face of a preceding mandrel (1201, 1503, 1603, 1405, 1701, 1901, 2505) is approximate to a forward face of a trailing mandrel (1201, 1503, 1603, 1405, 1701, 1901, 2505); and sequentially wrapping each mandrel (1201, 1503, 1603, 1405, 1701, 1901, 2505) with the composite material (1401, 1501, 2603, 1103, 1601) in a helical orientation.