Multilayer Composite Distribution in Structural Volumes
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Solution Overview
Problem
Designing multilayer composite structures is challenging due to the difficulty in determining the distribution of multiple layers within a three-dimensional structure, which is time-consuming, requires extensive CAD modeling skills, and can be error-prone, especially when dealing with complex shapes and performance constraints.
Innovation Solution
The development of computational methods and apparatus that use layer transformation guides and isocontours to efficiently distribute and reorder layers within the structure, providing rapid alternative distributions and guiding the cutting of layers from flat sheets, while reusing data from prior calculations to reduce computational intensity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional CAD tools and manual trial-and-error methods are used to determine layer distribution, then design flexibility and adaptability are maintained, but the design process becomes extremely time-consuming and computationally intensive
Solution Approach 1:
The patent pre-calculates and stores layer configuration data for various possible layer positions and configurations before the actual design process. When a layer needs to be relocated, the system can quickly retrieve pre-computed configuration data instead of performing full recalculations, significantly reducing the time required for layer distribution adjustments.
Solution Approach 2:
The patent implements selective recalculation by identifying only those layers and regions that are affected by a relocation operation. Instead of recalculating the entire multilayer structure, the system focuses computational resources on local areas where changes occur, reducing overall computational intensity while maintaining accuracy.
2Manufacturing precision
If extensive CAD modeling skills and manual processes are used, then design accuracy can be maintained, but the process requires considerable computer storage and powerful computing resources
Solution Approach 1:
The patent divides the multilayer structure into discrete, independently manageable layers. Each layer's configuration data is stored and processed separately, allowing the system to handle complex structures through modular computation rather than requiring monolithic computational resources. This segmentation enables accurate tracking and manipulation of individual layers while reducing overall system complexity.
Solution Approach 2:
The patent creates and stores digital representations (copies) of layer configuration data that can be rapidly retrieved and modified. These digital models serve as virtual prototypes that can be manipulated computationally without requiring physical prototypes or extensive manual modeling, reducing the need for powerful hardware while maintaining design accuracy.
3Reliability
If manual trial-and-error layer distribution is performed, then design constraints can be evaluated, but the process becomes error-prone and difficult to reproduce
Solution Approach 1:
The patent implements an automated feedback mechanism that evaluates layer distributions against design constraints and provides systematic guidance for improvements. The system automatically assesses whether relocated layers meet performance criteria and guides subsequent relocation decisions, eliminating the error-prone manual trial-and-error process while maintaining design constraint compliance.
Solution Approach 2:
The patent systematically varies layer configuration parameters (such as layer positions, orientations, and sequences) according to defined rules and constraints. By controlling parameter changes through automated algorithms rather than manual adjustments, the system ensures reproducible results that can be consistently regenerated, eliminating the variability and errors associated with manual processes.
Data Source
AI summary
Apparatus and methods for designing multilayer structures are described. The multilayer structures may be of simple or complex shapes having a volume to be filled by multiple layers of composite material. The composite material may include fiber/polymer composites. The methods facilitate distribution and reordering of layers within the multilayer structure during the design phase. Dimensional data for each layer within the structure may be provided as output data and used to cut “flat” patterns for each layer. The methods and apparatus can accelerate design and development of high-strength, composite multilayer structures.