Pultruded Web Core Sandwich Structures for Simpler Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fluted core sandwich structures are expensive and labor-intensive to manufacture due to the need for mandrel wrapping, separate production of flutes and noodles, and time-consuming layup processes.
Innovation Solution
The use of pultrusion-formed web structures with a middle support portion and flared end portions, joined to facesheets to form a monolithic unit, reduces manufacturing complexity by integrating the web structures into a single continuous structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fluted core sandwich structures are manufactured using traditional methods with separate flutes and noodles, then structural integrity is maintained, but manufacturing cost and labor intensity increase significantly
Solution Approach 1:
The patent combines separate flutes and radius filler noodles into a single integrated fluted core structure. The flutes are formed with curved corners that directly provide the radius filler function, eliminating the need for separate noodle components. This integration reduces manufacturing steps, lowers labor intensity, and simplifies the overall structure while maintaining the structural integrity and load-bearing capabilities of both the flutes and radius filler.
2Strength
If curved corners are added to flutes for better structural properties, then structural integrity improves, but void spaces are created requiring additional filler material
Solution Approach 1:
The fluted core structure integrates the radius filler function directly into the curved corners of the flutes themselves. The flutes are formed with rounded corners that provide the necessary structural support and fill the void spaces between flutes and facesheets, eliminating the need for separate radius filler noodle components while maintaining structural integrity.
3Productivity
If separate production of flutes and noodles is used, then manufacturing flexibility is maintained, but production time and labor costs increase
Solution Approach 1:
The fluted core structure is manufactured as a single integrated component rather than assembling separate flutes and radius filler noodles. This consolidation reduces the number of manufacturing steps, eliminates the need for separate production lines for flutes and noodles, and significantly decreases assembly time and labor requirements while maintaining manufacturing flexibility.
Data Source
AI summary
A panel is disclosed, including a first facesheet, a second face sheet, and a plurality of pultrusion-formed web structures. Each web structure has a middle support portion, a first end portion, and a second end portion. The first end portion of each web structure is attached to the first facesheet and the second end portion of each web structure is attached to the second facesheet. The middle support portion, first end portion, and second end portion of each web structure form a single monolithic structure.