3D Lattice Composite Strain Limiter for Aircraft Stiffness
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Solution Overview
Problem
Aircraft structures face challenges in maintaining sufficient stiffness while addressing three-dimensional stresses and the need for lightweight materials for fuel efficiency and payload capability.
Innovation Solution
A three-dimensional (3-D) composite structure is developed, comprising a 3-D lattice structure with struts, a matrix phase surrounding the lattice, and a strain limiting structure positioned at or near the center of the lattice, all formed using additive manufacturing techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If foam cores are used to create lightweight sandwich structures, then weight is reduced, but stiffness and strength are compromised
Solution Approach 1:
The patent employs 3-D lattice structures with controlled porosity as core materials. These lattice cores provide intermediate mechanical properties between solid and foam materials, achieving weight reduction while maintaining sufficient stiffness and strength through the open-cell geometric architecture that allows load distribution.
Solution Approach 2:
The patent creates composite sandwich structures combining face sheets with 3-D lattice cores. This composite approach integrates materials with different properties - the face sheets provide surface strength while the lattice core provides lightweight structural support, achieving superior overall performance compared to homogeneous materials.
2Strength
If 3-D lattice structures replace foam cores, then stiffness and strength are improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes additive manufacturing technology to produce 3-D lattice structures with complex geometries that would be difficult or impossible to manufacture using conventional methods. This manufacturing approach enables the realization of optimized lattice architectures with varying cell sizes, shapes, and densities tailored to specific structural requirements.
3Strength
If strain limiting structures are added to the lattice center, then ultimate strength is enhanced, but device complexity increases
Solution Approach 1:
The patent incorporates strain limiting structures specifically positioned at the centers of 3-D lattice cells where stress concentrations occur during compressive loading. This localized reinforcement strategy targets critical areas without adding complexity throughout the entire structure, allowing the lattice to deform more uniformly and delaying catastrophic failure.
Data Source
AI summary
A three-dimensional (3-D) composite structure has a 3-D lattice structure that includes a plurality of struts, a matrix phase surrounding the 3-D lattice structure, and a strain limiting structure positioned at or near a center of the 3-D lattice structure. The strain limiting structure is fixed to at least one of the plurality of struts. The 3-D composite structure can be made using additive manufacturing techniques.