Nested Laminated Metallic Structure for Complex 3D Forming

Solution Overview

Problem

Forming complex shapes from metallic laminates is challenging due to issues like bond degradation and internal strain imbalances, requiring complex, costly, and time-consuming processes.

Innovation Solution

The method involves forming preformed metallic sheets of graduated sizes into nested arrangements, bonding them with an adhesive, and then machining them into a final shape to create a laminated metallic structure with improved strength, damage tolerance, and reduced material waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If metallic laminates are formed into complex shapes, then the structure can achieve desired geometric configurations, but the adhesive bond degrades and internal strain imbalances are introduced

Engineering Contradiction:

Improvecomplex shapeVSAvoidadhesive bond integrity

Core Design Contradiction:

ShapeVSReliability

Solution Approach 1:

The patent applies preliminary action by pre-forming each metallic sheet into its final complex three-dimensional shape before lamination. This allows the adhesive bond to be established on already-formed surfaces, avoiding the degradation that occurs when bending after bonding. The sheets are then stacked and bonded in their final configurations, eliminating the need for post-bonding forming operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the complex structure into multiple pre-formed metallic sheets that are stacked in a laminated arrangement. Each sheet is independently formed to the desired complex shape, and then they are bonded together. This segmentation allows each layer to maintain its structural integrity while achieving the overall complex geometry through the stacked configuration.

Inventive Principle:

Principle #1Segmentation

2Shape

If metallic laminates are formed into complex shapes, then the structure can achieve desired geometric configurations, but internal strain imbalances between layers are introduced

Engineering Contradiction:

Improvecomplex shapeVSAvoidinternal strain balance

Core Design Contradiction:

ShapeVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary action by pre-forming each metallic sheet into its final complex three-dimensional shape before lamination. This allows the adhesive bond to be established on already-formed surfaces, avoiding the degradation that occurs when bending after bonding. The sheets are then stacked and bonded in their final configurations, eliminating the need for post-bonding forming operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies local quality by ensuring that each individual sheet in the laminate stack has uniform thickness and consistent material properties. This local uniformity prevents internal strain imbalances between layers, as each layer contributes equally to the overall structure without introducing differential stresses. The consistent pre-forming process ensures that local variations do not create global strain issues.

Inventive Principle:

Principle #3Local quality

3Shape

If traditional multi-step curing and reheating processes are used, then complex shapes can be formed, but the manufacturing process becomes complex, costly, and time consuming

Engineering Contradiction:

Improvecomplex shapeVSAvoidmanufacturing process complexity

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-forming each metallic sheet into its final complex three-dimensional shape before lamination. This allows the adhesive bond to be established on already-formed surfaces, avoiding the degradation that occurs when bending after bonding. The sheets are then stacked and bonded in their final configurations, eliminating the need for post-bonding forming operations.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent extracts the complex multi-step curing and reheating processes from the manufacturing workflow by performing all forming operations before bonding. This eliminates the need for subsequent heating, curing, and forming steps, significantly simplifying the manufacturing process while maintaining the ability to produce complex shapes.

Inventive Principle:

Principle #2Taking out (Extraction)

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

This approach allows for the creation of lightweight, high-strength laminated metallic structures with enhanced damage tolerance and reduced material waste, suitable for aerospace applications and other complex geometries.

Implementation Method 1

thin sheets of metallic material that are bound together by an adhesive to produce a structure

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Data Source

PatentEP3722090B1Laminated metallic structure and method of making the same

Publication Date: 2024.08.28 THE BOEING CO

Figure 1
Figure 2A~3B
Figure 4~5B

AI summary

A method of forming a laminated metallic structure includes steps of: (1) providing a first preformed-metallic sheet having a three-dimensional shape of a first graduated three-dimensional size; (2) providing a second preformed-metallic sheet having the three-dimensional shape of a second graduated three-dimensional size; (3) nesting the second preformed-metallic sheet in the first preformed-metallic sheet; and (4) bonding the first preformed-metallic sheet and the second preformed-metallic sheet together.