Efficient sub-structures
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Solution Overview
Problem
Current honeycomb-like structures for aircraft and other applications are uniform and cannot be varied, limiting their ability to meet specific engineering requirements for load and stress conditions, and they are undesirably heavy due to design limitations.
Innovation Solution
The use of additive manufacturing to create honeycomb-like structures with varying cell sizes, wall thicknesses, and shapes, allowing for tailored strength and weight distribution, using materials like high-temperature epoxy and aluminum, and incorporating lightening holes to reduce weight while maintaining stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If uniform honeycomb structures are used due to manufacturing limitations, then ease of manufacture is improved, but adaptability to different load and stress conditions deteriorates
Solution Approach 1:
The patent applies local quality by varying the honeycomb cell structure in different regions of the same component. Different zones have different cell sizes, shapes, or wall thicknesses tailored to specific load requirements. This allows the structure to have optimized local properties without requiring separate manufactured parts, thus maintaining ease of manufacture while improving adaptability to different stress conditions throughout the component.
2Device complexity
If uniform honeycomb structures are used, then device complexity is reduced, but strength distribution according to engineering requirements deteriorates
Solution Approach 1:
The patent employs parameter changes by systematically varying honeycomb structural parameters (cell size, shape, wall thickness) across different regions of the component. This allows the strength and stiffness to be optimized in specific areas where higher loads are expected, while maintaining lighter weight in lower-stress regions. The continuous variation of parameters within a single manufactured structure achieves superior strength distribution without significantly increasing device complexity.
3Strength
If heavier materials are used to increase strength, then strength is improved, but weight of moving object deteriorates
Solution Approach 1:
The patent applies local quality by creating regions of higher structural density only where strength is required. By varying cell size and wall thickness locally, the structure achieves higher strength in critical areas without increasing the weight of the entire component. This localized reinforcement approach optimizes the strength-to-weight ratio by placing material only where it is structurally necessary.
Solution Approach 2:
The patent segments the honeycomb structure into multiple zones with different structural characteristics. Each zone is optimized for its specific functional requirements, allowing the component to achieve overall strength through the combined effect of differentiated regions rather than requiring uniform heavy construction throughout. This segmentation enables weight reduction while maintaining necessary strength levels.
Data Source
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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 honeycomb-like cells, and a second plurality of honeycomb-like cells, different than the first plurality of honeycomb-like cells.