Lightweight Component Honeycomb Core Reinforcement
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Solution Overview
Problem
Existing lightweight components struggle to absorb higher loads without significant weight increases, particularly in aircraft interior walls where stability and rigidity are critical, especially when integrating folding seats and stretcher pass-throughs.
Innovation Solution
A lightweight component design featuring a honeycomb core with cutouts on both sides, covered by prepreg layers that extend from the lower edge to the upper edge for structural reinforcement, and an outermost E-Glass fabric layer, allowing for efficient load transfer and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional cover layers are added to increase load-bearing capacity, then strength is improved, but weight increases
Solution Approach 1:
The patent applies local quality by providing additional cover layers only in specific regions where higher loads are expected, rather than uniformly across the entire component. The honeycomb core has varying cell wall thicknesses in different areas, and the additional cover layers are strategically placed to reinforce these specific high-stress zones, thereby improving load-bearing capacity without adding unnecessary weight to the entire structure.
Solution Approach 2:
The patent segments the cover layers into multiple discrete layers with different orientations and material compositions. Instead of using a single thick cover layer, the structure uses multiple thinner layers (including carbon fiber reinforced plastic layers and glass fiber reinforced plastic layers) that can be independently optimized for weight and strength requirements in different regions.
2Stability of the object's composition
If honeycomb cell walls are thickened to increase rigidity, then stability is improved, but weight increases
Solution Approach 1:
The patent implements local quality by varying the honeycomb cell wall thickness according to the local load requirements. Rather than uniformly thickening all cell walls, the design provides thicker cell walls in regions subject to higher stresses and loads, while maintaining thinner cell walls in low-stress areas. This selective thickening approach enhances rigidity where needed without proportionally increasing the overall weight of the honeycomb structure.
3Strength
If cover layers extend beyond honeycomb edges to provide reinforcement, then strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the honeycomb core with recesses or stepped surfaces that match the extension pattern of the additional cover layers. This preliminary shaping of the honeycomb core allows the cover layers to be easily positioned and bonded in their extended configurations without requiring complex post-assembly operations, thereby reducing manufacturing complexity despite the extended cover layer design.
Data Source
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AI summary
A lightweight component comprises face sheets (20, 60, 70-76) as pairs of prepregs or stacks and a honeycomb core, wherein the face sheets (20) adjacent to the honeycomb core on both sides have a woven fabric as reinforcing fibers. The outermost first face sheet completely covers the honeycomb core (25). At least one further face sheet (60, 70-76) is provided, which covers only a partial area of the lightweight component (10) and which comprises at least one prepreg, each designed as at least one unidirectional layup. The honeycomb core has milled recesses on both sides, the arrangement, dimensions, and depth of which correspond to the at least one further face sheet in the finished lightweight component, so that the outer surfaces of the lightweight component have a smooth appearance.