Triangular Prism Core Beam with Triaxial Fabric Cover
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Solution Overview
Problem
Existing lightweight beam manufacturing techniques, such as pultrusion and filament winding, face challenges with mandrel removal and resource strain, and lack efficient methods for achieving optimal rigidity and minimal weight.
Innovation Solution
A lightweight beam structure featuring a triangular prism core with a triaxial fabric cover and reinforcement rods, allowing for a mandrel-free formation process that enhances strength and reduces weight by using a core that remains integrated within the beam.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If filament winding around a mandrel is used to form lightweight beams, then the beam structure can be created, but the mandrel removal becomes difficult and resource strain increases
Solution Approach 1:
The patent extracts the mandrel from the final beam structure by using a soluble or removable core form that dissolves or falls away after the composite material cures, eliminating the need for complex mandrel removal processes while maintaining ease of manufacture
Solution Approach 2:
The patent applies preliminary action by pre-positioning the mandrel within the mold cavity before composite layup, allowing the mandrel to serve as an internal support during manufacturing that automatically becomes part of the beam structure or can be easily removed after curing
2Productivity
If traditional pultrusion or filament winding methods are used, then beam production is achieved, but resource strain increases and manufacturing efficiency decreases
Solution Approach 1:
The patent segments the manufacturing process into discrete steps: placing rods in a mold cavity, laying up composite material layers, and curing. This segmentation allows for simpler, more efficient production compared to continuous pultrusion or filament winding, reducing resource strain while maintaining productivity
Solution Approach 2:
The patent uses disposable mold cavities and consumable rod materials that are inexpensive and single-use, eliminating the need for expensive, complex equipment maintenance and reducing overall resource strain compared to traditional manufacturing methods
3Weight of moving object
If hollow beam structures are used to reduce weight, then weight reduction is achieved, but structural strength and rigidity are compromised
Solution Approach 1:
The patent uses composite materials consisting of rods embedded in composite material layers, creating a lightweight yet strong structure that maintains both weight reduction and structural strength through the synergistic combination of different materials
Solution Approach 2:
The patent applies local quality by positioning rods at specific locations within the beam structure where strength is most needed, while using thinner composite material layers in other areas, optimizing the balance between weight and strength throughout the beam
Data Source
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AI summary
A lightweight beam (10) may have a triangular prism core (12) and a triaxial fabric cover (14) wrapped around the core (12), with at least one rod (16) proximate an apex of the core (12). The rod (16) may extend substantially parallel to a centerline (18) of the core (12). Multiple lightweight beams (10) may be joined to form a larger lightweight structure.