Paper Prepreg Honeycomb Assembly for Near-Net Shape Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing honeycomb structures are complex, require multiple steps of resin application and curing, and generate significant waste when forming irregular shapes, while also being limited by the need for specific process equipment based on material thickness.
Innovation Solution
A method involving the sequential placement of prepreg sheets and rods with rectangular cross-sections, followed by temperature treatments to adhere and harden the resin, allowing for the formation of honeycomb structures in a simpler, cost-effective process that reduces waste and enables irregular shapes without additional adhesives.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional expansion or corrugation processes are used to manufacture honeycomb structures, then structural properties and strength are improved, but the manufacturing process becomes complex and requires multiple steps including resin application and curing
Solution Approach 1:
The manufacturing process is segmented into distinct phases: placing rods with adhesive, forming the honeycomb structure, and then curing. This segmentation allows each step to be optimized independently and simplifies the overall process by breaking down the complex multi-step conventional methods into manageable stages.
Solution Approach 2:
Adhesive is applied to the rods before the honeycomb structure is formed, rather than applying resin after formation. This preliminary action eliminates the need for subsequent resin application and multiple curing steps, significantly simplifying the manufacturing process while maintaining structural strength.
2Shape
If conventional methods are used to form irregular honeycomb shapes, then design flexibility is improved, but material waste increases significantly due to cutting and shaping operations
Solution Approach 1:
Instead of forming regular honeycomb blocks and then cutting them into irregular shapes (which causes waste), the method inverts the approach by directly forming the honeycomb structure into the desired irregular shape during the initial formation process. This eliminates subsequent cutting operations and minimizes material waste.
Solution Approach 2:
The process allows for parameter changes in the forming stage, such as adjusting rod placement patterns and forming pressures, to directly create irregular shapes without requiring post-forming cutting or shaping operations, thereby reducing material waste.
3Strength
If multiple resin application and curing steps are used to manufacture honeycomb structures, then structural integrity is improved, but energy consumption increases
Solution Approach 1:
Adhesive is applied preliminarily to the rods before structure formation, eliminating the need for multiple subsequent resin application and curing steps. This single preliminary adhesive application maintains structural integrity while significantly reducing the cumulative energy consumption of multiple curing cycles.
Solution Approach 2:
The adhesive application step is merged with the rod placement step, and the structure formation and final curing are combined into a single integrated process. This merging eliminates the need for separate resin application and multiple curing steps, reducing energy consumption while maintaining structural integrity.
4Manufacturing precision
If specific process equipment is used for each material thickness in conventional methods, then manufacturing precision is improved, but equipment versatility deteriorates
Solution Approach 1:
The forming equipment is designed with universal capabilities to handle different prepreg sheet thicknesses and honeycomb configurations using the same basic process steps. The equipment can be adapted to different materials and thicknesses without requiring specialized dedicated equipment for each case, maintaining manufacturing precision through consistent process control.
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 method simplifies the manufacturing process, reduces energy consumption, and allows for the production of honeycomb structures with near-net shapes by eliminating multiple resin application and curing steps, while utilizing the same equipment for varying prepreg sheet thicknesses.
Implementation Method 1
exposing the assembly of honeycomb structures to a temperature that softens the resin for provisionally adhering the formed prepreg sheets to each other
Implementation Method 2
exposing the assembly of honeycomb structures with the rows of rods inside to a temperature that causes hardening of the resin
Data Source
Figure 1a~1c
Figure 1d~1f
Figure 2a~2d
AI summary
A method for manufacturing an assembly of honeycomb structures comprising the alternating placement of rows of rods (1.1, 1.2, 3.1, 3.2, 4.1, 4.2) and prepreg sheets, (5, 6) optionally exposing the assembly of honeycomb structures to a temperature that softens the resin for provisionally adhering the formed prepreg sheets to each other at the locations where two prepreg sheets(5, 6) are in contact to provisionally consolidate the honeycomb structure, exposing the assembly of honeycomb structures with the rows of rods (1.1, 1.2, 3.1, 3.2, 4.1, 4.2) inside to a temperature which hardens the resin, and removing the rows of rods, characterized in that the rods have a rectangular cross section and that the prepreg sheet is a paper sheet comprising resin. Also claimed are an assembly of honeycomb structures, a sandwich panel and shaped articles and an apparatus.