Honeycomb Structural Body Reinforcement Sheet Bonding
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Solution Overview
Problem
Conventional methods for manufacturing large-sized honeycomb structural bodies with curved surfaces face challenges in achieving satisfactory appearance and mechanical strength due to the need for preliminary bonding of cores with foamed adhesives, which can result in local dents and inadequate adhesive strength when cured in a single heating process.
Innovation Solution
A method involving the use of multiple cores with a honeycomb structure bonded with foamed adhesive in a direction increasing the number of pores, covered by at least one face sheet and reinforcement sheets placed between the face sheet and the cores, where the reinforcement sheets cover the foamed adhesive, allowing for simultaneous bonding and curing in a single heating process, eliminating the need for preliminary bonding and reducing manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cores are preliminarily bonded with foamed adhesive and then heated under pressure with skin prepreg, then the honeycomb structural body can be manufactured, but the process becomes complex and local dents occur on the skin surface
Solution Approach 1:
The skin prepreg is placed on the cores before heating, and the reinforcement sheet is positioned to cover the foamed adhesive area in advance. This preliminary arrangement allows the skin to be protected from direct contact with the expanding adhesive, preventing dents while maintaining bonding effectiveness.
Solution Approach 2:
A reinforcement sheet is introduced as an intermediary element between the skin prepreg and the foamed adhesive. This intermediate layer prevents the skin from直接接触 the expanding adhesive, eliminating local dents while still allowing the adhesive to perform its bonding function.
2Productivity
If foamed adhesive is used to bond multiple cores, then the cores can be joined together, but the adhesive strength becomes inadequate when cured in a single heating process
Solution Approach 1:
The patent combines foamed adhesive with reinforcement sheets made of composite materials to create a hybrid bonding system. The reinforcement sheet provides additional structural support and strength to the bonding interface, compensating for the inadequate adhesive strength of the foamed adhesive alone.
3Length of stationary object
If multiple cores are preliminarily bonded before placing skin prepreg, then large-sized honeycomb structural bodies can be manufactured, but preliminary bonding traces remain visible
Solution Approach 1:
The patent merges the preliminary bonding operation with the final skin application by placing the skin prepreg over the already-bonded cores. This integration allows the skin to cover and hide the bonding traces, achieving both large-scale manufacturing and smooth surface appearance.
Solution Approach 2:
The reinforcement sheet is strategically positioned to cover only the areas where foamed adhesive is applied, extracting and hiding the unwanted bonding traces from the visible surface while leaving the rest of the skin surface smooth and uniform.
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 simplifies the manufacturing process, prevents local dents, and enhances the mechanical strength and appearance of the honeycomb structural body, enabling higher-quality products with reduced manufacturing costs and eliminating the need for preliminary bonding traces.
Implementation Method 1
The preliminary bonding of the cores is often carried out with foamed adhesives that inflate by heat.
Implementation Method 2
the cores are preliminarily bonded by heat curing of the foamed adhesive
Implementation Method 3
The laminated skin prepreg(s) and the bonded cores are heated under pressure.
Implementation Method 4
The preliminary bonding of the cores is often carried out with foamed adhesives that inflate by heat. Therefore, when manufacturing a large-sized honeycomb structural body, the cores are preliminarily bonded by heat curing of the foamed adhesive
Data Source
AI summary
A honeycomb structural body includes multiple cores, at least face sheet, and at least one reinforcement sheet. The multiple cores each have a honeycomb structure, and are bonded to each other with foamed adhesive in a direction in which the number of multiple pores formed by the honeycomb structure increases. The at least one face sheet is adhered to the multiple cores so as to cover the multiple pores. The reinforcement sheet is placed between the multiple cores and the at least one face sheet, at a position where the reinforcement sheet covers the foamed adhesive.