Hollow Ceramic Core Composite Panels Bonding
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Solution Overview
Problem
Current composite structures capable of withstanding extreme operating conditions, such as high temperatures, are often bulky, expensive, and have short lifespans, with limited bonding areas between core structures and face sheets, which restricts their weight reduction and cost-effectiveness.
Innovation Solution
The use of composite panels with a plurality of hollow cells and a pliable matrix material to bond components, accommodating dimensional mismatches and enhancing bonding between the ceramic core structure and face sheets, while reducing material usage and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional composite structures are used to withstand extreme operating conditions, then strength and thermal resistance are improved, but weight and cost increase
Solution Approach 1:
The core structure is divided into multiple hollow cells instead of a solid monolithic structure. This segmentation maintains structural strength while significantly reducing material usage and weight. The hollow cells are arranged in a pattern that provides structural integrity while minimizing the amount of ceramic matrix composite material required.
Solution Approach 2:
The core structure employs a porous or hollow cellular configuration rather than a solid structure. This allows the core to maintain load-bearing capacity while using less material, thereby reducing weight and cost. The porous/hollow structure provides the necessary mechanical properties through strategic material placement rather than uniform density.
2Strength
If traditional composite structures are used to withstand extreme operating conditions, then strength and thermal resistance are improved, but manufacturing cost increases
Solution Approach 1:
By segmenting the core into hollow cells, the manufacturing process can utilize more efficient production methods such as additive manufacturing or modular assembly. This segmentation allows for reduced material consumption and potentially lower manufacturing costs while maintaining the required strength for extreme operating conditions.
Solution Approach 2:
The invention changes the structural parameters from solid to hollow cellular configuration, which can lead to more cost-effective manufacturing. This parameter change allows for optimized material usage and potentially simplified production processes while maintaining structural integrity.
3Device complexity
If limited bonding areas are used between core structures and face sheets, then manufacturing complexity is reduced, but bonding strength and reliability decrease
Solution Approach 1:
The bonding interface is extended from a limited area to a larger surface area by utilizing the hollow cell structure. The face sheets can bond to multiple surfaces of the hollow cells, effectively increasing the bonding area in three-dimensional space while maintaining manageable manufacturing complexity through the modular cell design.
Data Source
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AI summary
A method (200) of assembling a composite panel (100) includes disposing a pliable matrix material (190) between a first side (141) of a ceramic core structure (120) and a ceramic matrix composite face sheet (110), wherein the ceramic core structure (120) comprises a plurality of hollow cells (130) defined by a plurality of walls (132) extending from the first side (141) of the ceramic core structure (120) to a second side (143) of the ceramic core structure (120) opposite the first side (141); and densifying the pliable matrix material (190) to bond the pliable matrix material (190) with the ceramic core structure (120) and the ceramic matrix composite face sheet (110). The pliable matrix material (190) may comprise a liquid carrier, a powder, and a polymeric binder.