Lattice Panel Structure for Weight Reduction and Rigidity
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Solution Overview
Problem
Existing lightweight panel structures require multiple production processes, composite materials, and adhesives, making them complex and inefficient for applications where weight reduction and rigidity are critical, such as in aircraft components.
Innovation Solution
A three-dimensional lattice panel structure fabricated using a single homogenous material through processes like machining, injection molding, or 3D printing, featuring a two-dimensional pattern of offset holes that create orthogonal support posts, eliminating the need for adhesives and multiple assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If multiple production processes and composite materials are used to create lightweight panel structures, then weight reduction is achieved, but manufacturing complexity and assembly requirements increase
Solution Approach 1:
The patent merges multiple production processes and material layers into a single integrated manufacturing process. By using one-sided or two-sided drawing processes to form the lattice structure directly from a single sheet of material, the invention eliminates the need for separate production processes and assembly steps required by composite structures, thereby reducing manufacturing complexity while maintaining weight reduction benefits
Solution Approach 2:
The patent segments the panel into a lattice structure with repeating geometric patterns that create rigid three-dimensional forms from a single sheet. This segmentation allows the panel to achieve high strength-to-weight ratio through the lattice geometry itself, eliminating the need for additional reinforcement layers or composite materials that would increase manufacturing complexity
2Strength
If composite materials and adhesives are used to bond panel components, then structural strength is improved, but manufacturing complexity and assembly time increase
Solution Approach 1:
The invention combines the functions of multiple materials and bonding processes into a single homogenous material formed through drawing. The single sheet material is formed into a three-dimensional lattice structure that inherently provides both strength and rigidity, eliminating the need for separate bonding operations and adhesive materials
Solution Approach 2:
The lattice structure is designed to be self-supporting and self-rigidifying through its geometric configuration. The interlocking three-dimensional lattice pattern provides structural integrity without requiring external adhesives or bonding agents, allowing the panel to be manufactured as a single integral piece that is both strong and easy to manufacture
3Weight of moving object
If material is removed to create lattice structures, then weight is reduced, but structural rigidity may be compromised
Solution Approach 1:
The patent transitions from a two-dimensional sheet to a three-dimensional lattice structure through drawing processes. By creating depth and volume in the lattice pattern, the structure gains enhanced rigidity and load-bearing capacity that compensates for the material removal, achieving weight reduction without compromising structural integrity
Solution Approach 2:
The lattice structure is designed with varying local densities and thicknesses optimized for specific load paths. Material is strategically removed from low-stress areas while maintaining or enhancing material concentration in high-stress regions, allowing weight reduction while preserving or improving structural rigidity where needed
Data Source
Figure 1
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AI summary
A three dimensional lattice panel structure having a multitude of mutually offset holes formed in a respective top and bottom of the panel and intersecting to form voids with interspersed support posts interconnecting the top and bottom of the panel in areas not encompassed by the mutually offset holes.