Aircraft Composite Panel with Kite-Shaped Voids for Antenna Integration
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Solution Overview
Problem
Aircraft composite panels face a challenge in balancing structural robustness with the need to minimize electromagnetic interference (EMI) for antennas, as thicker materials enhance structural integrity but increase EMI, while thinner materials reduce EMI but compromise strength.
Innovation Solution
The design incorporates a core structure with kite-shaped voids arranged in a repeating pattern, bounded by walls that extend substantially perpendicular to the surface, allowing for reduced material thickness while maintaining mechanical strength and minimizing electromagnetic wave absorption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thicker composite panel materials are used to enhance structural integrity, then mechanical strength is improved, but electromagnetic interference increases
Solution Approach 1:
The patent applies porous materials by incorporating a foam core structure with controlled voids and cells within the composite panel. This foam core provides structural support and mechanical strength while the porous nature creates pathways for electromagnetic waves to pass through with reduced interference, effectively resolving the contradiction between structural integrity and EMI performance
Solution Approach 2:
The patent uses composite materials by combining multiple materials with different properties - specifically integrating a foam core with composite skins or facings. This multi-material approach allows the dense composite layers to provide structural strength while the foam core minimizes electromagnetic interference, achieving both requirements simultaneously
2Object-affected harmful factors
If thinner composite panel materials are used to reduce electromagnetic interference, then EMI is minimized, but structural strength is compromised
Solution Approach 1:
The foam core structure utilizes porous materials to achieve both EMI reduction and structural support. The controlled porosity allows electromagnetic waves to pass through while the foam's cellular structure provides compressive strength and rigidity, preventing the panel from being too thin while still minimizing EMI
Solution Approach 2:
The patent applies dimensionality change by transitioning from a solid two-dimensional panel structure to a three-dimensional foam core structure with embedded cells and voids. This adds a vertical dimension of complexity that allows the panel to maintain strength through the foam's internal architecture while reducing the effective material thickness that electromagnetic waves must traverse
3Strength
If more material is used in the composite panel, then structural robustness is improved, but electromagnetic wave transmission is hindered
Solution Approach 1:
The composite material system combines foam core with outer skin layers to create a multi-functional structure. The foam provides bulk structural robustness while the thin skin layers maintain antenna signal efficiency, achieving both structural reliability and communication reliability without requiring excessive material
Solution Approach 2:
The porous foam structure allows electromagnetic waves to pass through the panel thickness with reduced attenuation. The air-filled cells within the foam create a lower dielectric constant path that facilitates better signal transmission while the overall panel structure maintains structural robustness
Data Source
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AI summary
Core structures (120) for composite panels (75) of an aircraft (10), composite panels (75) and aircraft (10) including the core structures (120), and methods (200) of manufacturing the composite panels (75) are disclosed herein. The core structures (120) include a first side (140), a second side (150), and a connecting region (160) that interconnects an upper portion (142) of the first side (140) with an upper portion (152) of the second side (150). The first side (140), the second side (150), and the connecting region (160) at least partially define an antenna housing (62), which defines a housing volume (64) configured to contain an aircraft antenna (60) of the aircraft (10), and an electromagnetic wave transmission region (66) configured to permit electromagnetic waves to pass therethrough. The electromagnetic wave transmission region (66) defines a plurality of kite-shaped voids (130) arranged in a repeating pattern and bounded by a corresponding plurality of walls (170), at least 10% of which extends at least substantially perpendicular to a surface (122/124) that bounds the electromagnetic wave transmission region (66).