Welded Honeycomb Core Structure for Stable Crush Strength
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Solution Overview
Problem
The existing honeycomb structures, particularly welded metal honeycombs, exhibit unstable crush curves and inadequate specific strength, limiting their energy absorption capabilities, especially in high-temperature and high-pressure environments, and are not suitable for special scenarios due to material and bonding strength limitations.
Innovation Solution
A honeycomb core material is formed by welding honeycomb corrugated bands with uniformly distributed welding spots, where the distance between adjacent spots is less than or equal to the side length at the node, and incorporating concave-convex strips to enhance crush strength and stability, using laser or resistance spot welding for fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If adhesive bonding is used to manufacture honeycomb structures, then the crush strength curve is stable, but the bonding strength fails in high-temperature and high-pressure environments
Solution Approach 1:
The patent replaces adhesive bonding (chemical connection) with laser welding or resistance spot welding (direct metal fusion), eliminating the bonding strength limitation in high-temperature environments while maintaining crush strength stability through precise welding parameter control and uniform welding spot distribution
Solution Approach 2:
The patent changes the connection method from adhesive bonding to welding, and optimizes welding parameters (welding spot distance d ≤ side length A, uniform distribution) to achieve both stable crush strength curve and high reliability in extreme environments
2Ease of manufacture
If aluminum or paper material is used for honeycomb bonding, then the manufacturing process is simple, but the crush strength is limited
Solution Approach 1:
The patent uses metal materials (aluminum alloy, stainless steel, titanium alloy) with superior mechanical properties compared to traditional aluminum or paper, achieving higher crush strength while maintaining manufacturing feasibility through standardized welding processes
Solution Approach 2:
The patent changes the material type from aluminum or paper to high-strength metal alloys, and optimizes material parameters (thickness, alloy composition) to achieve enhanced crush strength while keeping the manufacturing process manageable
3Adaptability or versatility
If welded connection is used to manufacture honeycomb structures, then the material selection is flexible, but the crush curve fluctuation is large and unstable
Solution Approach 1:
The patent applies local quality optimization by precisely controlling welding spot distribution (uniform distribution with distance d ≤ side length A) and welding parameters at each node, ensuring consistent local bonding quality that results in stable overall crush curve across different metal materials
Solution Approach 2:
The patent optimizes welding parameters (spot distance, welding energy, welding speed) and structural parameters (node geometry, wall thickness) to achieve stable crush curve characteristics while maintaining material selection flexibility for different application requirements
4Reliability
If non-bonded welded metal honeycomb is used, then the high-temperature and high-pressure environment resistance is improved, but the specific strength is inadequate
Solution Approach 1:
The patent optimizes material parameters (selecting high-strength metal alloys with appropriate thickness) and welding parameters (ensuring complete penetration and strong fusion) to achieve both high-temperature/high-pressure resistance and adequate specific strength, eliminating the inadequacy of conventional welded honeycombs
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 approach ensures high stability and adjustable crush strength, preventing cracking and distortion during compression, and maintains stable crush strength even under high-temperature and high-pressure conditions, meeting requirements for aerospace and nuclear energy applications with improved manufacturing efficiency.
Implementation Method 1
honeycomb element nodes are welded by laser or resistance spot welding
Implementation Method 2
honeycomb element nodes are welded by laser or resistance spot welding
Data Source
AI summary
Provided is a honeycomb core material. The honeycomb core material is formed by welding a plurality of honeycomb corrugated bands, and includes a plurality of honeycomb elements. The honeycomb corrugated band includes free edges (1) and node edges (2) that are continuously arranged. The node edges that are correspondingly welded together form a honeycomb element node, and honeycomb element nodes are welded by laser or resistance spot welding. Welding spots of spot welding are uniformly distributed, a distance between two adjacent welding spots in a direction perpendicular to a cross section of the honeycomb element is d, a side length at the honeycomb element node is A, and a value of d is less than or equal to a value of A.