Embedded Conductor Honeycomb Core for Lightweight Signal Routing
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Solution Overview
Problem
Existing methods for routing electrical, optical, and fluid signals or power in composite structures, such as aircraft, often result in increased weight and interference due to the need for thick skins to embed conductors, which complicates integration with structural components and increases overall system weight.
Innovation Solution
A honeycomb core with embedded conductors, where the conductors are placed between interconnected cell walls, allowing for adhesion and extension through the cells to connect with other systems without thickening the structural skins, thereby maintaining structural integrity while enabling signal or power transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conductors are embedded in sandwich panel face sheets or skins, then signal or power transmission is enabled, but the thickness of the face sheets increases to unacceptable levels
Solution Approach 1:
The patent moves the conductor embedding location from the two-dimensional face sheets to the three-dimensional core structure. Conductors are placed within the core's cell walls or between core layers, utilizing the depth dimension of the sandwich panel to route conductors without affecting face sheet thickness.
Solution Approach 2:
The patent extracts the conductor routing function from the face sheets and relocates it to the core structure. This separation allows the face sheets to maintain their optimal thin structural thickness while the core handles the conductor integration.
2Reliability
If conductors are embedded in sandwich panel face sheets or skins, then signal or power transmission is enabled, but the overall weight of the system increases
Solution Approach 1:
By relocating conductors to the core structure, the patent avoids increasing face sheet thickness, thereby preventing the associated weight increase. The core material already present in the sandwich panel is utilized to house the conductors.
Solution Approach 2:
The patent merges the conductor routing function with the existing core structure. Instead of adding separate conductor layers to the face sheets, the conductors are integrated into the core, combining structural support and electrical routing functions in a single element.
3Reliability
If conventional cable routing methods are used around structural components, then signal transmission is achieved, but considerable effort and expense are expended on attachment and routing
Solution Approach 1:
The patent combines multiple functions into the core structure: structural support, insulation, and conductor routing. This integration eliminates the need for separate cable management systems and reduces the number of attachment points required.
Solution Approach 2:
The core structure serves as an intermediary that facilitates conductor routing between face sheets and through the panel structure. The core's cellular geometry provides natural pathways for conductor placement, simplifying the routing process.
Data Source
AI summary
A honeycomb core includes a first wall secured to a second wall and a conductor disposed therebetween. A honeycomb cell is formed between the first wall and the second wall and the conductor is configured to extend through the cell and a point where the first wall and the second wall are secured together.