Composite Unit Cell Matrix for Lightweight Multifunctional Structures
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Solution Overview
Problem
Existing components designed to handle multiple types of loading are often excessively heavy, bulky, and costly due to their homogeneous structure, which complicates additive manufacturing and increases material usage, making it difficult to create cost-effective, lightweight multifunctional structures with improved load-bearing and service life characteristics.
Innovation Solution
A composite unit cell matrix structure is fabricated using additive manufacturing and consolidation processes, comprising a first section of unit cells with a specific tensile strength and crack growth resistance, a second solid section with different properties surrounding the unit cells, and a third section that surrounds both, allowing for efficient handling of various loads without compromising strength or crack resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If homogeneous structures composed of a single material are used to handle all types of loading, then the component can handle multiple loads, but the component becomes excessively heavy, bulky, and expensive
Solution Approach 1:
The patent applies local quality by creating a composite structure where different materials are placed in specific locations within the component. The first material is positioned in regions requiring high strength and fatigue resistance, while the second material is placed in regions requiring different properties, allowing each material to optimally handle the specific loading conditions in its location rather than using a single homogeneous material throughout
Solution Approach 2:
The patent directly implements composite materials by combining two or more distinct materials with different properties within a single component structure. This composite construction enables the component to handle multiple types of loading (mechanical, thermal, electrical) simultaneously while maintaining optimized weight, as each material contributes its specific advantageous properties to the overall structure
2Reliability
If the structure is designed larger than necessary to maintain safety factor for fatigue life, then fatigue life is sufficient, but the component becomes excessively heavy and bulky
Solution Approach 1:
The composite structure applies local quality by concentrating the high-strength, high-fatigue-resistance material in specific regions where stress concentrations and fatigue-critical areas exist, rather than uniformly distributing material throughout the entire component. This localized placement of high-performance material maintains sufficient fatigue life while minimizing overall component weight
3Ease of manufacture
If additively manufacturing an entire structure is performed, then the structure can be manufactured, but the manufacturing process becomes time intensive
Solution Approach 1:
The patent applies segmentation by dividing the component into distinct sections or regions that can be manufactured separately using different processes or materials, then assembling them into the final composite structure. This segmentation allows each section to be optimized for its specific manufacturing requirements and enables parallel manufacturing of multiple sections, reducing overall manufacturing time compared to additively manufacturing the entire structure as a single piece
4Adaptability or versatility
If multiple materials are used within the structure, then multifunctional characteristics are achieved, but the additive manufacturing process difficulty increases
Solution Approach 1:
The patent applies segmentation by dividing the component into distinct sections that can be manufactured separately using different materials and processes, then assembling them into the final composite structure. This segmentation simplifies the manufacturing process by allowing each section to be optimized for its specific material requirements rather than attempting to manage multiple materials simultaneously in a single additive manufacturing process
Data Source
AI summary
A structure is provided. The structure defines a first direction, a second direction, and a third direction, the three directions orthogonal to each other. The structure includes a first section, a second section, and a third section. The first section includes a plurality of unit cells joined together, wherein the first section has a first average tensile strength and a first average crack growth resistance. The second substantially solid section is within and surrounding each unit cell of the plurality of first section unit cells, wherein the second section has a second average tensile strength and a second average crack growth resistance, the second average tensile strength different from the first average tensile strength and the second average crack growth resistance different from the first average crack growth resistance. The third section surrounds the first section and the second section.