Sandwich Panel Infill Geometry Mapping for Uniform Interfaces
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional additive manufacturing of sandwich panels results in irregular and inconsistent topology at the interfaces between the inner core and face sheets, leading to manufacturing challenges and stress concentrations.
Innovation Solution
A method and system for generating a panel infill geometry using a driver mesh and reference unit cell mesh, which are mapped onto hexahedral elements to create a consistent topology through basis functions, resulting in a panel infill mesh that connects face sheets with uniform interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a prior art infill geometry with orthogonally-repeating structural pattern is used, then the manufacturing process is simple, but the topology at the interfaces between inner core and face sheets becomes irregular and inconsistent
Solution Approach 1:
The infill geometry is segmented into multiple unit cells, each containing a portion of the structural pattern. This segmentation allows the interface topology to be controlled at each unit cell level, ensuring consistency where unit cells meet the face sheets while maintaining the overall repeating pattern for manufacturing simplicity.
Solution Approach 2:
The patent applies different geometric configurations to unit cells based on their location. Unit cells at interface locations with the face sheets are designed with specific patterns that ensure consistent topology, while interior unit cells follow the standard orthogonally-repeating pattern. This local differentiation resolves the contradiction between manufacturing simplicity and interface consistency.
2Ease of manufacture
If a prior art infill geometry is used, then the manufacturing process is straightforward, but stress concentrations occur at certain interface locations
Solution Approach 1:
Unit cells located at interface positions with the face sheets are designed with specific geometric patterns that optimize stress distribution. These interface unit cells have modified configurations compared to interior unit cells, creating smoother stress transitions and eliminating stress concentrations while maintaining the overall manufacturing straightforwardness of the additive process.
Solution Approach 2:
The patent预先 designs the unit cell patterns to anticipate and prevent stress concentration issues before manufacturing. By carefully selecting and positioning specific unit cell configurations at interface locations during the design phase, the structure is pre-configured to distribute stresses evenly, avoiding the need for post-manufacturing corrections or reinforcements.
3Device complexity
If an orthogonally-repeating structural pattern is used, then the design is simple, but the interface shapes present manufacturing challenges
Solution Approach 1:
The design segments the infill pattern into discrete unit cells that can be independently configured. This segmentation allows the creation of consistent interface shapes by carefully selecting which unit cells are placed at interface locations, maintaining design simplicity through the repeating pattern while ensuring manufacturability through controlled interface geometry.
Solution Approach 2:
Instead of allowing the orthogonally-repeating pattern to dictate the interface shapes (which causes manufacturing challenges), the patent inverts the approach by first defining the desired consistent interface topology and then selecting unit cell patterns that achieve this topology. This reversal of the design logic resolves the manufacturing challenges while preserving design simplicity.
Data Source
AI summary
A method of generating a panel infill geometry of a sandwich panel, includes providing a driver mesh representing a panel mid-surface of a sandwich panel. The driver mesh is comprised of a plurality of quadrilateral elements. The method further includes providing a reference unit cell mesh configured to fit exactly within a cube. The reference unit cell mesh is comprised of a unit infill mesh interconnecting a pair of unit face sheet meshes. The method additionally includes mapping a plurality of the reference unit cell meshes respectively onto a plurality of hexahedral elements respectively associated with the plurality of quadrilateral elements, through the use of basis functions defined on each of the plurality of quadrilateral elements in a manner causing adjustment of the size and shape of the plurality of reference unit cell meshes to conform respectively to the plurality of hexahedral elements.