Folded Core Panel Airflow and Bonding Design
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Solution Overview
Problem
Honeycomb panels in aircrafts face issues with moisture ingress and delamination due to lack of airflow and inadequate bonding surface area, requiring excessive adhesive which increases weight and manufacturing complexity.
Innovation Solution
A folded core panel with a corrugated zigzag pattern featuring peaks and valleys, providing increased bonding surface area and airflow channels to minimize moisture ingress and reduce adhesive usage, while distributing shear forces effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If a honeycomb core is used in a panel, then the panel achieves lightweight and rigid properties, but the core is prone to moisture ingress and delamination due to lack of airflow
Solution Approach 1:
The core structure transitions from a traditional two-dimensional honeycomb pattern to a three-dimensional folded corrugated configuration. This dimensional change creates internal voids and pathways that enable airflow through the core, allowing moisture to escape while maintaining the lightweight and rigid properties of the panel.
Solution Approach 2:
The folded core structure inherently creates a porous configuration with interconnected voids and channels. This porous architecture facilitates air circulation throughout the core, preventing moisture accumulation and eliminating the need for additional drainage holes or airflow modification systems.
2Weight of moving object
If a honeycomb core is used in a panel, then the panel achieves lightweight properties, but a relatively large amount of adhesive is required to prevent delamination under shear force
Solution Approach 1:
The transition to a three-dimensional folded core structure dramatically increases the bonding surface area between the core and face sheets. This enhanced surface area distributes shear forces more effectively across multiple contact points, reducing the adhesive quantity needed while preventing delamination.
Solution Approach 2:
The folded core structure creates multiple nested levels and contact surfaces within the core architecture. These nested configurations provide numerous bonding interfaces between the core and face sheets, increasing the effective bonding area and reducing adhesive requirements compared to a flat honeycomb structure.
3Strength
If a honeycomb core is used in a panel, then the panel achieves rigid properties, but the bonding surface area between core and face sheets is insufficient
Solution Approach 1:
The three-dimensional folded core structure provides multiple bonding surfaces at different elevations and orientations. This dimensional complexity increases the total bonding surface area between the core and face sheets, enhancing the mechanical connection while maintaining panel rigidity.
Data Source
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AI summary
A folded core panel disclosed herein that includes a folded core having peaks and valleys characterized by a corrugated zigzag pattern. The folded core may include an airflow channel. The airflow channel may provide an egress to reduce the concentration of moisture in the folded core. The folded core may be formed from a single piece of material. The folded core may have varying face slopes depending on the force distribution requirements at the location of the peak. One or more folded cores may be stacked to form a stacked core.