Offset Stacking Finite Sub-Laminate Cards for Tapered Composite Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional composite laminate structures face inefficiencies due to their discrete nature, requiring thick sub-laminates for symmetry and balance, leading to excessive thickness, waste, and manufacturing complexities, especially when trying to minimize laminate thickness or taper structures, which limits achievable stiffness and strength characteristics.
Innovation Solution
The use of finite sub-laminate cards with offset stacking to form dual-tapered composite laminate structures, allowing for easier tapering and reduced weight while maintaining structural integrity, by sliding cards like playing cards to achieve optimal laminate configurations without the need for mid-plane symmetry.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional composite laminate structures use symmetric and balanced ply layers to emulate metal strength characteristics, then structural strength and stability are improved, but laminate thickness increases excessively and manufacturing complexity increases
Solution Approach 1:
The patent applies asymmetry by eliminating the requirement for mid-plane symmetry in laminate stacking sequences. The method allows asymmetric stacking where plies can be dropped individually or in groups at different locations, enabling tapered configurations without requiring symmetric counterbalancing plies. This resolves the contradiction by achieving structural integrity through optimized asymmetric layouts rather than forced symmetry.
Solution Approach 2:
The patent segments the laminate into discrete ply groups that can be independently managed and dropped. Instead of treating the laminate as a continuous symmetric structure, the method divides it into selectable ply groups where each group can be positioned and terminated independently, enabling precise thickness control and tapering while maintaining structural performance.
2Stability of the object's composition
If conventional composite laminate structures require mid-plane symmetry with multiple ply groups, then structural balance is improved, but manufacturing complexity and error potential increase
Solution Approach 1:
The patent eliminates mid-plane symmetry requirements, allowing asymmetric stacking sequences where plies can be dropped at different locations on opposite faces. This asymmetry simplifies manufacturing by removing the complex constraint of matching ply patterns while maintaining structural balance through optimized layup designs that achieve required performance without forced symmetry.
Solution Approach 2:
The method segments the laminate into independently controllable ply groups that can be dropped selectively. This segmentation simplifies manufacturing by allowing each ply group to be managed as a discrete unit, reducing the complexity of tracking and matching symmetric patterns while maintaining structural integrity through controlled ply termination.
3Strength
If conventional composite laminate structures use thick sub-laminates to achieve desired thickness, then structural integrity is improved, but weight increases and tapering capability decreases
Solution Approach 1:
The patent applies local quality by allowing ply drops at specific locations rather than requiring uniform thickness throughout. Individual ply groups can be terminated at different positions, creating locally optimized thickness distributions. This enables weight reduction in non-critical areas while maintaining structural integrity in load-bearing regions, achieving tapered configurations without compromising overall strength.
4Strength
If conventional composite laminate structures require multiple ply groups for symmetry, then structural performance is improved, but achievable stiffness and strength characteristics are limited
Solution Approach 1:
The patent enhances adaptability by eliminating symmetry constraints, allowing asymmetric stacking sequences that can be optimized for specific performance requirements. Engineers can drop plies at different locations and in different patterns to achieve tailored stiffness and strength characteristics for each application, rather than being limited to discrete symmetric configurations.
Solution Approach 2:
The method improves versatility by segmenting the laminate into independently controllable ply groups. This segmentation enables flexible configuration where each ply group can be positioned and terminated to achieve desired performance characteristics, allowing continuous optimization of stiffness and strength rather than being constrained to fixed symmetric patterns.
Data Source
AI summary
Described are various dual-tapered composite laminate structures. These structures may comprise a plurality of finite sub-laminate cards, each one of the plurality of cards having the same shape and size as the other ones of the plurality of cards and having opposing surfaces oriented in a card plane, opposing primary edges of the planar surfaces, and opposing secondary edges of the planar surfaces, the opposing secondary edges being perpendicular to the opposing primary edges. The finite sub-laminate cards are stacked relative to one another in a successively offset manner. Also described are methods of stacking and sliding (for offset) the finite sub-laminate cards. Tapered fuselage skin and fuel tank covers are also considered.