Honeycomb Core Perforation to Keep Vent Holes Open During Coating
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Solution Overview
Problem
Existing methods for manufacturing honeycomb cores in composite sandwich structures face issues such as hole plugging during phenolic coating, debris contamination, and undesirable structural features due to drilling, which are size-dependent and costly.
Innovation Solution
A manufacturing system and method that perforates fibrous material with holes before coating, using a perforation assembly to create aligned holes, applies adhesive strips, cuts layers, and expands them to form a honeycomb panel, with a repellant coating at holes to prevent solution clogging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If holes are added prior to the phenolic coating process, then venting capability is improved, but holes become filled with phenolic resin which plugs the holes
Solution Approach 1:
The patent applies a release agent coating to the honeycomb core surfaces before the phenolic coating process. This preliminary action prevents the phenolic resin from adhering to the core, ensuring holes remain open during subsequent coating operations while maintaining venting capability.
Solution Approach 2:
The release agent acts as an intermediary substance between the phenolic resin and the honeycomb core. This intermediary layer prevents direct contact and adhesion between the resin and core surfaces, allowing holes to stay open while still enabling the coating process to proceed.
2Manufacturing precision
If holes are drilled through sides of the honeycomb core after the phenolic coating process, then hole plugging is avoided, but debris is formed which contaminates surfaces
Solution Approach 1:
The patent performs the perforation operation before the phenolic coating process rather than after. This preliminary action eliminates the need for post-coating drilling, thereby preventing debris generation and surface contamination while still achieving the required hole openness for venting.
3Ease of manufacture
If drilling holes after coating is performed, then accessibility and cost issues are avoided, but undesirable structural features occur to the honeycomb core
Solution Approach 1:
The patent performs perforation before coating and uses a release agent to prevent adhesion. This approach maintains structural integrity by avoiding post-coating drilling operations that could compromise the honeycomb core, while also preserving manufacturing accessibility and reducing costs.
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
This approach avoids drilling post-coating, reduces debris, and maintains open holes for venting, enhancing structural integrity and manufacturing efficiency.
Implementation Method 1
A repellant coating is applied to the honeycomb core prior to the phenolic coating process
Implementation Method 2
strips of adhesive are applied to the fibrous material, and the holes are spaced apart from the strips of adhesive
Data Source
AI summary
A manufacturing system to form a honeycomb core and a method of forming the same includes a sheet of fibrous material is fed into a perforation assembly. The sheet of fibrous material is perforated via the perforation assembly to form holes through the sheet of fibrous material. The sheet of fibrous material is cut to form layers. The layers are stacked on top of each other such that the holes of the layers align with each other and strips of adhesive bond the respective layers together to form a perforated stack. A coating is applied to the sheet of fibrous material at the holes. The perforated stack is expanded to form a honeycomb panel. The honeycomb panel is dipped in a solution, and the coating repels the solution. The solution adheres to the honeycomb panel except at the holes where the coating is applied to form the honeycomb core.