TPMS Core Repair Plug for Water-Resistant Composite Panels
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Solution Overview
Problem
Core structure panels, such as those used in aircraft, suffer from inconsistencies due to impacts or lightning strikes, which affect their mechanical properties and water tolerance, necessitating a replacement material with better mechanical properties and water resistance.
Innovation Solution
The use of a triply periodic minimal surface (TPMS) structure as a core plug, which is adhered to the core structure panel using a foam adhesive, providing improved mechanical properties and water tolerance through its unique lattice structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional honeycomb core is used in core structure panels, then the panel can be manufactured with conventional materials and processes, but the core is susceptible to water ingress and has limited mechanical properties and impact resistance
Solution Approach 1:
The patent employs a TPMS structure with controlled porosity that provides water resistance while maintaining mechanical properties. The unique lattice geometry of the TPMS core creates a water-resistant barrier while preserving structural integrity, solving the contradiction between porosity for strength and resistance to water ingress
Solution Approach 2:
The patent uses composite materials in the TPMS structure, combining different materials with complementary properties to achieve both high strength and water resistance. The composite nature of the TPMS core allows optimization of both mechanical properties and water tolerance simultaneously
2Force
If a traditional honeycomb core is used, then the manufacturing process is conventional and simple, but the core has limited impact resistance and energy absorption capability
Solution Approach 1:
The patent utilizes the curved, continuous surfaces of the TPMS structure to distribute impact forces throughout the core. The curved geometry provides superior impact resistance and energy absorption compared to traditional honeycomb structures, while the periodic nature maintains manufacturability
Solution Approach 2:
The patent optimizes geometric parameters of the TPMS structure (such as unit cell size, wall thickness, and lattice density) to achieve desired impact resistance and energy absorption properties. By adjusting these parameters, the core provides enhanced mechanical performance while controlling manufacturing complexity
3Reliability
If a core plug replacement repair method is used, then the damaged portion can be replaced, but the repair material typically matches the original material properties rather than improving them
Solution Approach 1:
The patent applies parameter changes by using a TPMS structure with optimized geometric parameters that provide superior mechanical properties and water tolerance compared to the original core. The repair plug uses the same TPMS technology to ensure both improved reliability and strength
Solution Approach 2:
The patent employs composite materials in the TPMS repair plug that provide both enhanced water tolerance and improved mechanical properties. The composite structure allows simultaneous achievement of higher strength and better water resistance in the repair material
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 TPMS structure enhances the mechanical properties and water resistance of the core structure panel, offering high impact resistance and energy absorption, while avoiding issues with water ingress and buckling.
Implementation Method 1
The core plug may include a TPMS structure and a foam adhesive that adheres the TPMS structure to the core
Data Source
AI summary
A method includes forming an opening in a core structure panel. The opening extends through a first laminate skin and at least partially through a core of the core structure panel. The method includes positioning a core repair plug in the opening. The core repair plug comprises a triply periodic minimal surface (TPMS) structure to replace the core removed during formation of the opening. The method includes adhering the TPMS structure to the core adjacent to the opening. The method also includes repairing the first laminate skin.