Tiered Honeycomb Load Structure for Uniform Load Distribution
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Solution Overview
Problem
Existing load structures, such as those used in vehicles, exhibit unpredictable weak areas due to varying contours and thicknesses, affecting their ability to withstand loads efficiently and increasing manufacturing costs.
Innovation Solution
A multi-dimensional load structure with a tiered configuration of layers, including a base layer and interior layers with varying thicknesses and materials, is manufactured by assembling, forming, and coating to enhance structural integrity and load-bearing capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If load structures are formed using corrugated wave board blocks or pre-molding geometric shapes, then the load structure can withstand loads, but unpredictable weak areas are created that affect structural integrity
Solution Approach 1:
The load structure is divided into multiple layers of honeycomb cores (first, second, and third honeycomb cores) with different orientations and configurations. Each layer segment contributes to the overall strength while distributing stress uniformly, eliminating weak areas that would occur in monolithic structures.
Solution Approach 2:
Different honeycomb core layers are strategically positioned with specific orientations (e.g., first core with ridges in first direction, second core with ridges in second direction) to provide localized strength where needed. The varying thickness and material composition of each layer address specific structural requirements at different locations.
2Adaptability or versatility
If load structures have varying contours and thicknesses, then they can be adapted to different applications, but manufacturing complexity and costs increase
Solution Approach 1:
The structure is segmented into multiple manufacturable layers that can be produced using standardized honeycomb core manufacturing processes. Each layer maintains relative simplicity in production while the assembled multi-layer structure achieves the required varying contours and thicknesses for different applications.
Solution Approach 2:
Multiple honeycomb core layers are nested within each other in a systematic arrangement, with each layer contained within the overall structure boundaries. This nesting approach allows complex three-dimensional contours to be achieved through stacked two-dimensional layers, simplifying manufacturing compared to forming the entire complex shape in one piece.
3Strength
If multiple layers with varying thicknesses and materials are assembled, then compressive strength and load distribution are enhanced, but manufacturing time and process complexity increase
Solution Approach 1:
The honeycomb cores and facing sheets are prepared as pre-fabricated components with specific thicknesses, materials, and orientations before assembly. This preliminary preparation allows the final assembly process to be more efficient, as components are ready for integration rather than requiring complex in-situ fabrication during assembly.
Solution Approach 2:
Multiple honeycomb core layers and facing sheets are combined in a single integrated assembly process to form the complete load structure. By merging the assembly of different layers and components into one coordinated operation, manufacturing time is reduced compared to producing each layer separately and assembling them in multiple stages.
Data Source
AI summary
A load structure may include a first honeycomb layer, a second honeycomb layer, and/or an attachment feature. The second honeycomb layer may be connected to the first honeycomb layer. The attachment feature may be connected to at least one of the first honeycomb layer or the second honeycomb layer. A method of manufacturing a load structure may include providing a first honeycomb layer, a second honeycomb layer, and an attachment feature, disposing an adhesive layer onto at least one of the first honeycomb layer or the second honeycomb layer, connecting an attachment feature to the first honeycomb layer or the second honeycomb layer, and/or disposing the first honeycomb layer onto the second honeycomb layer.