Composite Structural Panels via Mandrel Wrapping and Segmentation
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Solution Overview
Problem
Conventional methods for forming honeycomb-based structural panels are limited by specific materials and designs, making it challenging to create non-planar and varied composite structural panels with desired mechanical properties and weight characteristics.
Innovation Solution
The method involves wrapping a mandrel with composite tape to form a tube, cutting it into tubular structures, and arranging these structures to form a bonded grid with controlled fiber orientations and varying wall thicknesses, allowing for the creation of composite structural panels with customized properties and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional expansion or corrugation methods are used to form honeycomb cores, then manufacturing process is simplified, but material selection and design flexibility are limited
Solution Approach 1:
The patent segments the honeycomb structure into discrete modular units that can be independently formed and assembled. Each cell or group of cells can be manufactured separately using the mandrel wrapping method, then assembled to form the complete honeycomb core, enabling flexible material selection and design configurations while maintaining manufacturing simplicity
Solution Approach 2:
The patent employs composite materials by wrapping mandrels with layered composite tapes consisting of different fiber types and resin systems. This allows the honeycomb core to incorporate multiple materials (e.g., carbon fiber, glass fiber, aramid fibers) with complementary properties, achieving both manufacturing feasibility and enhanced design flexibility simultaneously
2Ease of manufacture
If conventional techniques are used to form honeycomb panels, then standard manufacturing processes are maintained, but non-planar panel formation is challenging
Solution Approach 1:
The patent utilizes curved mandrels with varying cross-sectional geometries to form non-planar honeycomb structures. By wrapping composite materials around three-dimensionally configured mandrels (including cylindrical, conical, and irregular shapes), the process naturally produces curved and non-planar panel geometries while maintaining standardized manufacturing procedures
Solution Approach 2:
The patent transitions from two-dimensional planar honeycomb formation to three-dimensional non-planar structures by introducing vertical and radial dimensional variations through specially configured mandrels. This enables the formation of complex geometries such as tapered sections, curved surfaces, and variable thickness regions within the honeycomb panel
3Adaptability or versatility
If composite tubes are cut into tubular structures, then varied lengths and shapes are achieved, but manufacturing steps increase
Solution Approach 1:
The patent performs preliminary actions by first forming complete composite tubes of desired length and configuration around mandrels before cutting them into smaller tubular structures. This pre-forming step establishes the basic geometry and fiber orientation, and subsequent cutting operations simply divide the pre-formed structure into required segments, minimizing additional manufacturing complexity
Solution Approach 2:
The patent segments the composite tube into multiple tubular structures of varying lengths and shapes through controlled cutting operations. By dividing the pre-formed tube at strategic locations, the process achieves diverse geometric configurations without requiring separate manufacturing for each segment, thereby reducing overall process complexity
4Strength
If fiber orientations are controlled during wrapping, then mechanical properties are optimized, but wrapping process complexity increases
Solution Approach 1:
The patent applies asymmetric fiber orientation patterns by wrapping composite tapes at different angles relative to the mandrel axis. By varying the wrap angle (e.g., 0°, 45°, 90°) in different regions of the tube, the process creates directionally optimized reinforcement that targets specific mechanical loading conditions without requiring complex multi-axis equipment
Solution Approach 2:
The patent incorporates dynamic fiber orientation control through automated wrapping systems that can adjust tape application angles in real-time during the wrapping process. This allows the fiber orientation to be dynamically varied along the tube length to match anticipated stress distributions, optimizing mechanical properties while maintaining a relatively simple single-axis wrapping mechanism
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
This approach enables the production of composite structural panels with enhanced mechanical strength, weight reduction, and tailored properties, such as compressive strength and energy absorption, suitable for diverse applications including aircraft components.
Implementation Method 1
applying very specific adhesive patterns to these sheets. The sheets are then stacked to form adhesive bonds
Implementation Method 2
bonding the composite tubular structures together by co-curing, co-bonding, or secondary bonding
Implementation Method 3
The composite tube is then cut into a plurality of composite tubular structures. In some examples, the composite tube is partially cured prior to the cutting
Data Source
AI summary
Described are novel composite structural panels and methods of forming such panels. In some examples, a method comprises wrapping a mandrel with a composite tape to form a composite tube. This wrapping operation allows forming composite tubular structures with any cross-sectional profiles defined by the mandrel. The wrapping is also used to control the fiber orientations in the composite tubular structures. The composite tube is then cut into composite tubular structures. In some examples, the composite tube is partially cured prior to the cutting, which allows removal of the mandrel while preserving the shape of the composite tube. This cutting operation allows forming composite tubular structures with different lengths, shapes, and orientations of the ends. The composite tubular structures are disposed on a support structure and are bonded to each other. In some examples, this bonding operation also involves final curing of the composite tubular structures.