Multi-blocks Hexagonal Core for Curved Composite Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The composite industry faces challenges in creating lightweight, mechanically robust parts with complex shapes, as existing core materials like honeycomb scaffolds and foam plaques require additional processing steps and materials to maintain mechanical properties and conformability, leading to increased weight and manufacturing complexity.
Innovation Solution
A multi-blocks structure composed of interconnected hexagonal columnar blocks with linking means that allow angular offset, enabling deformation into complex shapes and uniform resin distribution, eliminating the need for additional layers and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If honeycomb scaffold is used as core material, then lightweight property is improved, but resin infiltration into cells increases weight and complicates manufacturing
Solution Approach 1:
The core material is divided into discrete block elements arranged in a modular pattern, allowing resin to flow between blocks rather than infiltrating cellular structures. This segmentation prevents the harmful resin-cell interaction while maintaining the lightweight advantage.
Solution Approach 2:
The block interface acts as an intermediary structure that controls resin flow paths, directing resin to distribute uniformly across the core material without allowing deep infiltration into individual blocks, thereby simplifying manufacturing while preserving lightweight properties.
2Shape
If foam plaque is used as core material, then conformability is improved, but additional machining steps are required increasing manufacturing complexity
Solution Approach 1:
The block elements are pre-formed with surfaces and geometries that enable direct assembly into curved configurations without requiring post-manufacturing machining. The modular design allows the core to be shaped during assembly rather than requiring subsequent machining operations.
3Shape
If precut foam plaque is used, then conformability is improved, but resin distribution uniformity deteriorates
Solution Approach 1:
The core is segmented into multiple discrete blocks with controlled interfaces, creating numerous small channels that guide resin flow uniformly throughout the structure. This segmentation prevents resin pooling or starvation zones that occur with larger precut pieces.
Solution Approach 2:
The block interfaces are designed with specific geometric characteristics that locally control resin flow, ensuring uniform distribution across different regions of the core material while accommodating curved shapes.
4Strength
If additional airtight layers are provided to prevent resin infiltration, then weight increases, but mechanical properties are maintained
Solution Approach 1:
Instead of preventing resin contact with the core material using additional layers, the design converts the potential harm of resin infiltration into a benefit by using the resin-filled block interfaces as reinforcement channels that enhance mechanical properties without adding weight.
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 multi-blocks structure enhances mechanical properties through uniform resin distribution and reinforcement channels, simplifies handling and manufacturing, and maintains lightweight properties without additional materials, facilitating the production of composite parts with superior mechanical resistance and conformability.
Implementation Method 1
the linking means are located on the first side of the plate and are configured to leave interspaces between the blocks and to authorize an angular offset of each block with respect to the adjacent blocks, so that the plate is allowed to deform from a substantially straight configuration to a curved configuration
Implementation Method 2
the outer layers are usually strongly adhered to the core material by means of a resin which is infused in the space between the outer layers and the core material and then cured
Data Source
AI summary
The present invention relates to a multi-blocks structure intended to be used as the core material of a composite part, comprising a plurality of elementary hexagonal columnar shaped blocks, arranged adjacent one another in a honeycomb-like pavement and interconnected by linking means to form a unitary plate, wherein the linking means are located on the first side of the plate and are configured to leave interspaces between the blocks and to authorize an angular offset of each block with respect to the adjacent blocks, so that the plate is allowed to deform from a substantially straight configuration to a curved configuration at least in the area of the offset blocks. The invention also relates to a composite part comprising such a multi-blocks structure and to a method for manufacturing such a composite part.