Efficient sub-structures
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Solution Overview
Problem
Current honeycomb-like structures in aircraft components are uniform and cannot be varied, leading to design limitations such as undesirably high weight and inability to meet specific load and stress requirements, with trapped air causing instability during curing.
Innovation Solution
The use of additive manufacturing techniques to create honeycomb-like structures with varying cell sizes, wall thicknesses, and materials, including lightening holes, allows for tailored strength and weight distribution, enabling the creation of monolithic structures with customized cell patterns and materials like high-temperature epoxy and aluminum.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform honeycomb structures are used in aircraft components, then manufacturing is simplified, but weight reduction and structural optimization are limited
Solution Approach 1:
The patent applies local quality by varying honeycomb cell sizes, wall thicknesses, and material compositions at different locations within the structure. Larger cells with thinner walls are used in low-stress areas for weight reduction, while smaller cells with thicker walls are used in high-stress areas for structural strength, optimizing both weight and manufacturing feasibility
Solution Approach 2:
The honeycomb structure is segmented into multiple zones with different cell configurations (first plurality of cells with first size, second plurality of cells with second size). This segmentation allows tailored weight and strength distribution across the component while maintaining a single integrated manufacturing process through additive manufacturing
2Ease of manufacture
If uniform honeycomb structures are used, then production is easier, but specific load and stress requirements cannot be met
Solution Approach 1:
Different regions of the honeycomb structure have different cell sizes and wall thicknesses matched to local stress requirements. High-stress regions use smaller cells with thicker walls for maximum strength, while low-stress regions use larger cells with thinner walls, allowing the structure to meet specific load requirements while remaining manufacturable
Solution Approach 2:
The patent uses composite materials with varying material compositions in different honeycomb zones. Some regions use high-temperature epoxy while others use aluminum or other materials, allowing optimization of structural strength for specific load conditions while maintaining production ease through additive manufacturing
3Ease of manufacture
If air is trapped in honeycomb structures during curing, then manufacturing is simpler, but structural stability is compromised
Solution Approach 1:
The honeycomb structure inherently provides porous pathways that allow air to escape during curing. The interconnected cell structure creates natural ventilation channels that prevent air entrapment while maintaining manufacturing simplicity and curing stability
Solution Approach 2:
The segmented honeycomb cell structure creates multiple small chambers that facilitate controlled air flow during curing. This segmentation allows air to move systematically through the structure rather than being trapped in large voids, enhancing curing stability without complicating the manufacturing process
Data Source
AI summary
A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of cells, and a second plurality of cells, different than the first plurality of cells.