Curved Composite Honeycomb Weaving for Uniform Cell Deformation
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Solution Overview
Problem
Existing methods for producing alveolar structures with curved shapes using fibrous composite materials face challenges such as tension zones and non-uniform deformation, making it difficult to achieve regular structures, and require significant manual operations, which are not compatible with industrial production.
Innovation Solution
A method involving the production of a deployable fibrous structure by weaving, which enhances mechanical strength and cohesion, allowing for uniform deformation and shaping on curved surfaces, using weft and warp threads oriented at specific angles and multilayer or 3D interlock weaving, with optional pyrolysis and densification steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a deployable fibrous structure is made from stacking two-dimensional strata, then the structure can be produced, but the strata loosen in tension zones and deform non-uniformly when shaped on curved surfaces
Solution Approach 1:
The patent applies composite materials by combining multiple layers of woven fabric with specific thread orientations (0° and 90° relative to the curvature axis) to create a fibrous structure that maintains uniform deformation characteristics when shaped on curved surfaces. The composite nature of the woven layers provides both flexibility for curving and structural integrity to prevent non-uniform deformation.
Solution Approach 2:
The patent implements local quality by varying the orientation of warp and weft threads in different layers of the fibrous structure. Specifically, alternating layers have threads oriented at 0° and 90° to the curvature axis, creating local variations in mechanical properties that collectively enable uniform deformation across the entire curved surface while preventing strain concentration.
2Ease of manufacture
If manual operations are used to produce deployable fibrous textures, then the structure can be assembled, but the process is not compatible with industrial production
Solution Approach 1:
The patent applies preliminary action by pre-weaving the fibrous structure in a flat state with the desired thread patterns and layer configurations before shaping. This pre-preparation of the woven fabric layers with predetermined orientations allows the structure to automatically achieve the correct geometry when shaped, eliminating the need for manual assembly operations during production.
Solution Approach 2:
The patent replaces manual mechanical assembly operations with a automated weaving process that creates the fibrous structure in a single continuous operation. The weaving machine automatically interlaces threads in the specified patterns and orientations, substituting manual labor with automated textile manufacturing technology that is compatible with industrial production scales.
3Shape
If the fibrous structure is deformed following a curved shape, then curved honeycomb structures can be produced, but tension zones cause strata to loosen and prevent regular structure formation
Solution Approach 1:
The patent applies parameter changes by modifying the mechanical properties of the fibrous structure through controlled dehydration of the polymer matrix. This changes the physical state and rigidity parameters of the material, enabling it to maintain structural cohesion and resist tension-induced loosening while still allowing the necessary deformation to achieve curved shapes.
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
Enables the efficient and economical manufacturing of curved honeycomb structures with improved mechanical strength and uniformity, minimizing material losses and facilitating industrial-scale production.
Implementation Method 1
the texture is stretched in a direction perpendicular to the planes of the cutouts to give, by deformation, a honeycomb structure
Implementation Method 2
a step of polymerization of the fibrous structure
Implementation Method 3
a step of pyrolysis of the resin to transform said resin into ceramic
Data Source
Figure 1~2
Figure 3A
Figure 3B
AI summary
The invention relates to a method for producing a curved honeycomb structure, comprising the following steps: producing a deployable fibrous structure (100) by means of the multi-layer weaving of a plurality of layers of warp yarns and a plurality of layers of weft yarns, said fibrous structure comprising separating zones which extend through the thickness of the fibrous structure and are spaced from one another by linking portions between multiple layers of weft yarns, the linking portions being offset by one or more weft yarns in a direction parallel to that of the layers of weft yarns between each series of weave planes; impregnating the fibrous structure (100) with a precursor resin of a pre-determined material; deploying the fibrous structure (100) on a holding tool (50) such as to form, in the fibrous structure, a cell or honeycomb in each separating zone, said tool also having a curved shape corresponding to the shape of the honeycomb structure to be produced; polymerising the resin of the fibrous structure such as to form a curved honeycomb structure comprising a plurality of cells or honeycombs.