Non-Parallel Ribbon Honeycomb Structures for Curved Geometries
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Solution Overview
Problem
Current methods for forming non-planar honeycomb structures often introduce undesired stresses and sacrifice strength and stiffness, and are limited in their ability to produce a wide variety of shapes and sizes with minimal forming steps, leading to inefficiencies in manufacturing cost and time.
Innovation Solution
A method involving ribbons with non-parallel edges that are shaped and folded to form honeycomb structures with different cross-sectional shapes, allowing for the creation of a wide range of three-dimensional geometries without applying additional forces, thereby maintaining structural integrity and reducing manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If force is applied to deform flat honeycomb cells into non-planar shapes, then the desired curved shape is achieved, but stresses are introduced and strength/stiffness are sacrificed
Solution Approach 1:
The invention applies preliminary action by pre-forming the ribbons with non-parallel edges before assembly. The ribbons are designed with specific geometries that inherently guide them into the desired curved configurations during assembly, eliminating the need for post-assembly deformation forces that would compromise structural integrity.
Solution Approach 2:
The invention inverts the conventional approach by not deforming a flat honeycomb into a curved shape, but rather assembling pre-formed ribbons that naturally create the curved shape. Instead of applying force to change the shape of completed cells, the curvature is built into the fundamental geometry of the ribbon components themselves.
2Shape
If conventional methods are used to form non-planar honeycomb structures, then shaping is achieved, but manufacturing complexity and time increase
Solution Approach 1:
The invention segments the honeycomb structure into individual ribbons with non-parallel edges, each capable of being formed independently. This segmentation allows for simplified manufacturing of individual components that can be assembled into complex non-planar configurations, reducing overall manufacturing complexity.
Solution Approach 2:
The invention changes the fundamental geometric parameter of the ribbon edges from parallel to non-parallel. This parameter change enables the ribbons to naturally form curved configurations when assembled, providing design flexibility for various non-planar shapes without requiring complex forming equipment or processes.
3Adaptability or versatility
If ribbons with non-parallel edges are used, then a wide variety of three-dimensional shapes can be formed, but ribbon manufacturing complexity increases
Solution Approach 1:
By changing the edge geometry parameter from parallel to non-parallel, the invention enables a wide variety of three-dimensional shapes to be formed. The non-parallel edges create natural curvature when ribbons are assembled, providing versatility in designing different curved configurations while maintaining relatively simple manufacturing processes.
Solution Approach 2:
The invention introduces asymmetry by using non-parallel edges on the ribbons. This asymmetric geometry allows the ribbons to form curved and non-planar structures when assembled, providing versatility in creating various three-dimensional shapes. The asymmetric design is simple enough to manufacture using standard cutting and forming techniques.
Data Source
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AI summary
A method and apparatus for forming a ribbon configured for use in forming a honeycomb structure when the ribbon is in a folded state. The ribbon comprises a first edge and a second edge. At least one portion of the first edge is not parallel to at least one portion of the second edge when the ribbon is in an unfolded state.