Grid Base Structure for Additive Filling Without Honeycomb Adhesives
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Solution Overview
Problem
Existing methods for producing semi-finished objects using honeycomb panels face issues with adhesive failure, thermal stress, and structural discontinuity, limiting material choices and increasing production costs.
Innovation Solution
A method involving a laminar base element with section bars fastened to define restraint elements, onto which a filling material is applied using additive manufacturing, creating a grid structure with restraint elements to prevent slippage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If honeycomb panels are used to prevent filling material slippage, then adhesion is improved, but manufacturing complexity increases and material choices are limited
Solution Approach 1:
The base element is segmented into a grid pattern of raised portions that create discrete engagement features. This segmentation provides multiple localized adhesion points for the filling material without requiring a complex overall structure, thereby improving reliability while maintaining manufacturing simplicity
Solution Approach 2:
The base element features localized raised portions with specific geometric characteristics (engaging surfaces and engagement features) that are optimized for adhesion. This local quality enhancement at critical interfaces improves filling material retention without complicating the entire structure or limiting material selection
2Strength
If adhesive is used to join honeycomb structure to plates, then structural integrity is improved within thermal range, but reliability deteriorates outside thermal range due to adhesive degradation
Solution Approach 1:
The patent replaces the chemical bonding mechanism (adhesive) with a mechanical interlocking mechanism. The raised portions create engagement features that physically interlock with the filling material, providing thermal stability independent of adhesive properties while maintaining structural integrity across a wide thermal range
3Strength
If welding is used to join honeycomb structure to plates, then structural integrity is improved, but harmful thermal stress is generated affecting cavity interface
Solution Approach 1:
The patent replaces the thermal welding process with a mechanical interlocking system using raised portions and engagement features. This eliminates thermal stress generation while achieving equivalent or superior structural integrity through geometric interlocking, thereby removing the harmful thermal effect on the cavity interface
4Strength
If mechanical constraint (bolting) is used to join honeycomb structure, then structural integrity is improved, but risk of disrupting functional components increases
Solution Approach 1:
The base element incorporates localized raised portions that create engagement features positioned to avoid critical functional components. This localized geometric feature provides mechanical constraint and structural integrity without requiring bolts or fasteners that could disrupt the structural continuity or damage embedded functional elements
5Ease of manufacture
If traditional production methods are used, then manufacturing process is simple, but production costs increase and material choices are limited
Solution Approach 1:
The base element with raised portions serves multiple functions: it provides structural support, creates engagement features for filling material adhesion, and enables compatibility with various filling materials through geometric interlocking. This multi-functionality expands material choices and adaptability while maintaining a simple, universally applicable manufacturing process
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
The method reduces production costs and allows a wider range of materials to be used while ensuring the filling material adheres effectively, maintaining structural integrity across varying temperatures.
Implementation Method 1
applying, preferably by means of an additive manufacturing process, a filling material onto the laminar element bearing the restraint elements
Data Source
AI summary
A method for the production of an object comprises the steps of providing a base element, providing a plurality of section bars, and fastening the section bars to one surface of the base element; the method further comprises the steps of defining a plurality of restraint elements, which are active along a vertical axis with respect to the base element, by means of one or more of said section bars, and applying a filling material onto the base element at least in one engagement portion cooperatively defined between the surface and at least one of the restraint elements.