Metal Core Truss Panel Seamless Feature Embedding

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Solution Overview

Problem

Conventional methods for embedding features into composite materials like carbon fiber composites face challenges such as mechanical failure due to epoxy bond adhesion issues and time-consuming machining of metal inserts with threaded holes and complex features, which affect the structural integrity and stress capacity of the composite panels.

Innovation Solution

The method involves fabricating a sacrificial core truss panel with embedded features using techniques like stereolithography or 3D printing, followed by metal plating to create a metal core truss panel with seamlessly integrated features, eliminating the need for epoxy bonds and reducing machining time by integrating features directly into the truss structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional epoxy bonding methods are used to embed features into composite panels, then features can be attached to the panel, but the epoxy bond adhesion causes mechanical failure and reduces structural integrity

Engineering Contradiction:

Improvestructural integrityVSAvoidfeature attachment strength

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent removes the epoxy bonding layer entirely by using a sacrificial core panel made of the same composite material as the final panel. Features are embedded directly into the sacrificial panel during fabrication, eliminating the need for separate bonding operations and the associated adhesion failures.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Features are embedded into the sacrificial core panel during its initial fabrication process using automated fiber placement or similar techniques, before the panel is assembled into the final composite structure. This preliminary embedding ensures features are integral to the panel structure from the start.

Inventive Principle:

Principle #10Preliminary action

2Adaptability or versatility

If metal inserts with threaded holes and complex features are machined conventionally, then features can be created in the panel, but the machining process is time-consuming and reduces productivity

Engineering Contradiction:

Improvefeature complexityVSAvoidfabrication speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent combines feature fabrication with the core panel manufacturing process itself. Automated fiber placement systems deposit reinforcement fibers and resin to create both the panel structure and embedded features in a single integrated operation, eliminating separate machining steps.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention changes the fabrication parameter from post-manufacturing machining to in-process additive fabrication. By using automated fiber placement to build features directly during panel manufacturing, the process transitions from subtractive (machining) to additive (building), dramatically increasing productivity.

Inventive Principle:

Principle #35Parameter changes

3Strength

If features are embedded into ultra-low density core panels with honeycomb or truss structures, then the high strength-to-weight ratio is maintained, but the open porosity and minimal density make traditional embedding methods ineffective

Engineering Contradiction:

Improvestrength-to-weight ratioVSAvoidfeature embedding ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Features are embedded into the sacrificial core panel during its fabrication before it is assembled into the final ultra-low density panel structure. This preliminary embedding allows features to be integrated into the open-cell structure without requiring post-assembly modifications that would compromise the delicate honeycomb or truss geometry.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts the embedding process from the final panel structure and performs it on a sacrificial duplicate. This allows features to be created in a solid, manufacturable form that is then transferred to the ultra-low density panel, maintaining both the lightweight structure and functional features.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS11753734B2Method for embedding inserts, fasteners and features into metal core truss panels

Publication Date: 2023.09.12 CALIFORNIA INST OF TECH

AI summary

Systems and method for fabricating a metal core truss panel with seamlessly embedded features in accordance with embodiments of the invention are illustrated. One embodiment includes a method for producing a metal core truss panel composite, the method including fabricating a sacrificial core truss panel including a plurality of interconnected truss members and at least one embedded feature, and plating the sacrificial core truss panel with a layer of metal forming a metal core truss panel including a plurality of interconnected metal truss members and at least one seamlessly embedded metal feature.