Ventilated Honeycomb Aero-Structure for Moisture and Bonding Control

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Solution Overview

Problem

Honeycomb structures in aircraft are prone to moisture ingress and bonding issues due to closed cells, which can lead to structural failure and processing challenges in autoclave bonding operations.

Innovation Solution

The integration of a micro-lattice structure with a honeycomb core that allows airflow through their interface, enabling ventilation and addressing moisture issues, and utilizing a ventilation system to circulate air through the aircraft's airframe.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If honeycomb structures are sandwiched and bonded between opposing panels to achieve high strength to weight ratio, then structural strength is improved, but moisture ingress and bonding failure occur due to closed cells

Engineering Contradiction:

Improvestrength to weight ratioVSAvoidbonding reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent introduces a ventilated honeycomb structure where the closed cells are modified to include ventilation pathways. The honeycomb core maintains its load-bearing function while allowing air flow through the structure, preventing moisture accumulation and bonding failure. The ventilation channels are integrated into the honeycomb cell walls, creating a porous pathway system that preserves structural integrity while enabling moisture evacuation.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent employs a desiccant material as an intermediary substance placed within the honeycomb structure. This desiccant acts as a moisture-absorbing mediator between the external environment and the bonding interfaces, preventing moisture from reaching critical bonding areas. The desiccant can be positioned in select cells or distributed throughout the structure to provide localized moisture protection.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Stability of the object's composition

If closed honeycomb cells are used to maintain structural integrity, then structural stability is improved, but airflow for venting and cooling is blocked

Engineering Contradiction:

Improvestructural stabilityVSAvoidairflow capability

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The honeycomb structure is designed with ventilation channels integrated into the cell walls, creating a porous pathway system. These channels allow air to flow through the honeycomb core while the remaining solid material maintains structural stability. The cell walls are thinned or perforated in specific patterns to create airflow paths without compromising the load-bearing capacity of the overall structure.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The honeycomb structure is segmented into load-bearing regions and ventilation regions. Specific cells or portions of cells are designated as ventilation channels where material is removed or thinned to allow airflow. This segmentation allows different portions of the structure to serve different functions - some areas maintain structural integrity while others facilitate air circulation for cooling and moisture venting.

Inventive Principle:

Principle #1Segmentation

3Ease of manufacture

If unvented honeycomb structures are used in autoclave bonding operations, then manufacturing simplicity is maintained, but pressure buildup causes bonding failure and structure collapse

Engineering Contradiction:

Improvebonding process simplicityVSAvoidbonding success rate

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The ventilated honeycomb structure with integrated airflow channels enables pressure equalization during autoclave bonding operations. The porous ventilation pathways allow trapped gases to escape and external pressure to be evenly distributed throughout the structure, preventing localized pressure buildup that would cause bonding failure or structural collapse. This maintains the simplicity of the bonding process while significantly improving reliability.

Inventive Principle:

Principle #31Porous materials

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

This configuration enhances the durability of aircraft components by preventing moisture-related failures and simplifies the autoclave bonding process by allowing controlled airflow, improving processing efficiency and structural integrity.

Implementation Method 1

a ventilation system configured to circulate air through the ventilated aero-structure

Methodology Applied

Scientific EffectAir circulation: Convection

Implementation Method 2

The interface between the honeycomb core and the micro-lattice structure is configured to permit air flow to and from the honeycomb core via the micro-lattice structure

Methodology Applied

Scientific EffectAir flow through porous structure: Porosity

Data Source

PatentUS9321241B2Ventilated aero-structures, aircraft and associated methods

Publication Date: 2016.04.26 THE BOEING CO

AI summary

Ventilated aero-structures include a micro-lattice structure operatively coupled to a honeycomb core. The interface between the honeycomb core and the micro-lattice structure is configured to permit air flow to and from the honeycomb core via the micro-lattice structure. Aircraft include a ventilated aero-structure and a ventilation system configured to circulate air through the ventilated aero-structure. Some methods include coupling a micro-lattice structure to a honeycomb core. Some methods include utilizing a ventilated aero-structure to assemble an aircraft.