Monolithic Aerospace Panel Structure for Thermal Spreading
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Solution Overview
Problem
Aerospace panels constructed with composite sandwich structures face challenges in thermal management, radiation resistance, and manufacturing efficiency, particularly due to high thermal impedance, labor-intensive production, and the need for post-production attachment of separate parts for localized features.
Innovation Solution
The development of additively manufactured aerospace panels featuring a monolithic, joint-free structure composed of skins connected by a truss structure with lattice regions and truss members, which are integral and self-supporting, allowing for efficient thermal management and resistance to radiation, and enabling localized reinforcement and thermal spreading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite sandwich-structure panels are used for aerospace vehicles, then strength and light weight are achieved, but thermal impedance increases and manufacturing complexity increases
Solution Approach 1:
The patent merges the core material and skin layers into a single integrated structure printed as one continuous piece. This eliminates the adhesive bonds between separate layers, creating direct material contact that reduces thermal impedance while maintaining the sandwich structure's strength and light weight properties.
Solution Approach 2:
The patent uses composite materials with thermally conductive fillers (such as aluminum, copper, or graphite particles) embedded in the polymer matrix of the skin layers. This enhances the thermal conductivity of the skin materials themselves, reducing thermal impedance without compromising the structural strength.
2Strength
If composite sandwich-structure panels are manufactured using conventional methods, then structural integrity is achieved, but manufacturing time and labor costs increase
Solution Approach 1:
The patent combines multiple manufacturing steps (core placement, skin lamination, adhesive application, curing) into a single additive manufacturing process. The panel is printed as one continuous piece without sequential assembly steps, dramatically reducing manufacturing time while maintaining structural integrity through the layered printing process itself.
Solution Approach 2:
The additive manufacturing process creates self-supporting structures during printing, where each printed layer serves as its own support for subsequent layers. This eliminates the need for external tooling, fixtures, and post-manufacturing assembly operations, reducing both time and labor requirements while ensuring structural integrity.
3Adaptability or versatility
If separate parts are attached post-production for localized features, then functional requirements are met, but manufacturing complexity and labor costs increase
Solution Approach 1:
The patent integrates localized features such as shielding, reinforcement, and access ports directly into the panel structure during the additive manufacturing process. These features are printed as integral parts of the panel without requiring separate components or post-production attachment operations, reducing manufacturing complexity while maintaining design versatility.
Solution Approach 2:
The patent implements localized features with varying material properties or structural characteristics at specific locations within the panel. The additive manufacturing process allows different regions of the panel to have different densities, infill patterns, or material compositions tailored to local functional requirements, achieving adaptability without increasing overall manufacturing complexity.
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
The solution provides enhanced thermal performance, reduced weight, and manufacturing efficiency by integrating truss structures with lattice regions, improving resistance to radiation and debris impacts, while eliminating the need for secondary supports and post-processing.
Implementation Method 1
selective laser melting (SLM)
Implementation Method 2
direct metal laser sintering (DMLS)
Implementation Method 3
selective laser sintering (SLS)
Implementation Method 4
electron beam melting (EBM)
Implementation Method 5
at least one lattice region defining a lattice configured to eliminate secondary printing support
Data Source
AI summary
An aerospace panel includes a first skin, a second skin spaced apart from the first skin, and a first truss structure connecting the first skin to the second skin. The first truss structure includes a plurality of truss members. Each truss member is integral with the first skin and the second skin, such that the first skin, the second skin, and the first truss structure collectively form a single monolithic joint-free structure. At least one of the skins also includes at least one lattice region that includes a lattice grid and an array of openings.