Segmented Composite Support Frame for Curved Panel Mounting
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Solution Overview
Problem
Existing methods for manufacturing composite materials in curved shapes result in inefficiencies such as material waste, increased costs, and potential wrinkling due to deformation, leading to defective products.
Innovation Solution
A support body and mounting method that utilizes a frame structure composed of interconnected frame members with Z-shapes, formed from laminated composite materials, which are folded along linear directions to minimize wrinkling and facilitate efficient assembly, ensuring strength and reduced manufacturing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a flat rectangular laminate is cut out into a curved shape, then a component extending in a curved shape can be manufactured, but unnecessary material is generated and manufacturing costs increase
Solution Approach 1:
The support body is divided into multiple frame members that can be arranged along a curved array direction. Each frame member has a linear shape that is easier to manufacture, and together they form the curved support structure, avoiding the need to cut a single large laminate into a curved shape.
Solution Approach 2:
The invention transitions from using a single curved-shaped laminate to using multiple linear frame members arranged in space along a curved path. This dimensional arrangement allows the support body to achieve curvature without requiring curved-shaped individual components, thereby reducing material waste.
2Shape
If a sheet-like composite material is folded in a curved shape to manufacture a component, then the composite material can extend in a curved shape, but the composite material may be wrinkled due to deformation
Solution Approach 1:
The support body is segmented into multiple frame members with linear shapes. Each frame member maintains its linear geometry without requiring folding or curving, thus avoiding wrinkling. The curved appearance is achieved through the arrangement of these linear segments rather than deforming individual components.
3Shape
If preforms are deformed into an arc shape to manufacture an annular structural body, then the structural body can be formed, but the preforms may be wrinkled due to deformation
Solution Approach 1:
The annular support body is divided into multiple frame members that are arranged in an arc-like configuration. Each frame member maintains a linear shape without deformation, eliminating wrinkling issues. The overall arc shape is achieved through the spatial arrangement of these undistorted linear segments.
4Strength
If multiple frame members are connected to form a support body along a curved array direction, then support strength is ensured, but device complexity increases
Solution Approach 1:
Multiple frame members are connected through connecting parts to form an integrated support body. The connecting parts merge the individual frame members into a unified structure that provides continuous support along the curved array direction, ensuring support strength while maintaining manufacturing simplicity.
Data Source
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AI summary
A long frame (20) is provided with: a plurality of frame members (21) that have a longitudinal direction (LD) and a short direction (SD), have a first flange part (21a) folded along a folding line extending along the longitudinal direction (LD), and are arranged close to an inner peripheral surface of a surface plate (17) along an array direction (AD); and a plurality of first connecting parts (22) that connect each of the plurality of first flange parts (21a) to the surface plate (17). The frame (20) is further provided with at least one of a second connecting part (23) that connects second flange parts (21c) to each other and a third connecting part (24) that joins together end surfaces of a pair of frame members (21) arranged adjacent to each other in the array direction (AD) to connect the pair of frame members (21) arranged adjacent to each other.