Geodesic Composite Structures via Thermal Expansion

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Solution Overview

Problem

Manufacturing composite materials with strong structural properties in a cost-efficient manner is challenging, particularly for geodesic structures which are difficult to produce while maintaining high strength and structural integrity.

Innovation Solution

A method involving coupling reinforcement fibers to spherical components, inserting them into an enclosure, and heating to cause expansion, forming a geodesic structure with a polyhedron arrangement that distributes stress effectively in all directions, using fiber-reinforced small hollow spheres that deform into a three-dimensional lattice.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional composite materials are manufactured to achieve strong structural properties, then structural strength is improved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The geodesic structure is divided into multiple spherical components that can be independently manufactured and then assembled together. Each spherical component is a discrete unit that can be produced separately and then coupled to form the overall geodesic structure, simplifying the manufacturing process while maintaining structural strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses composite materials by combining reinforcement fibers with spherical components. The reinforcement fibers are coupled to the spherical components to create a composite structure that leverages the strengths of both materials - the spherical components provide structural framework while the reinforcement fibers enhance strength and stiffness.

Inventive Principle:

Principle #40Composite materials

2Stability of the object's composition

If geodesic structures are manufactured to maintain high strength and structural integrity, then structural integrity is improved, but manufacturing difficulty increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The complex geodesic structure is segmented into simpler spherical components that are easier to manufacture individually. These spherical components are then assembled through coupling to form the complete geodesic structure, reducing overall manufacturing complexity while preserving structural integrity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The spherical components undergo thermal expansion when heated during the manufacturing process. This parameter change allows the components to expand and interlock properly, forming the geodesic structure with high structural integrity without requiring complex assembly procedures.

Inventive Principle:

Principle #35Parameter changes

3Strength

If reinforcement fibers are coupled to spherical components to form geodesic structure, then structural strength is improved, but manufacturing steps increase

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The reinforcement fibers are coupled to the spherical components before assembly into the geodesic structure. This preliminary action allows the fibers to be pre-positioned and secured to the spherical components, streamlining the final assembly process and improving manufacturing efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The spherical components and reinforcement fibers are merged into a single integrated geodesic structure through coupling. This merging process combines multiple elements into one unified structure, reducing the number of separate manufacturing steps and improving overall productivity.

Inventive Principle:

Principle #5Merging (Combining)

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 cost-efficient production of high-strength geodesic structures suitable for aircraft components, providing structural integrity and high shear strength, and allows for repair of damaged components without requiring additional manufacturing steps.

Implementation Method 1

heating the enclosure to cause the plurality of spherical components to expand

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10633084B2Geodesic composite structures

Publication Date: 2020.04.28 BELL HELICOPTER TEXTRON INC

AI summary

In one embodiment, a method may comprise coupling a plurality of reinforcement fibers to a plurality of spherical components; inserting the plurality of spherical components into an enclosure; and heating the enclosure to cause the plurality of spherical components to expand, wherein the plurality of spherical components expands to form a geodesic structure, wherein the geodesic structure comprises a plurality of polyhedron components configured in a geodesic arrangement.