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  • 专利说明
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    • 专利摘要:
    APPARATUS AND METHOD FOR MANUFACTURING A SANDWICH STRUCTURE. A method and apparatus for making a sandwich structure. A cavity is formed in a core of the sandwich structure. A structural insert is placed inside the cavity. The structural insert comprises a first number of parts configured to receive a load and a second number of parts assembled with the first number of parts to form the structural insert.
    公开号:BR102014020218B1
    申请号:R102014020218-8
    申请日:2014-08-14
    公开日:2020-08-25
    发明作者:Peter Holemans
    申请人:The Boeing Company；
    IPC主号:
    专利说明:

    [0001] [0001] This description generally refers to aircraft and, in particular, aircraft structures. In addition, more particularly, the present description relates to a method and apparatus for structural inserts configured to receive loads on aircraft hull structures.
    [0002] [0002] Aircraft are being designed and manufactured with increasing percentages of composite materials. Composite materials are used in aircraft to decrease the weight of the aircraft. This reduced weight improves performance characteristics, such as payload capacities and fuel efficiency. In addition, composite materials provide a longer service life for various components in an aircraft.
    [0003] [0003] Composite materials are tenacious, lightweight materials, created by combining two or more functional components. For example, a composite material can include reinforcement fibers bonded in a polymer resin matrix. As another example, honeycomb structures are a class of composite materials. A honeycomb structure can be a sandwich honeycomb. With this type of structure, two layers are affixed to either side of a core. These layers can be considered a coating for the sandwich honeycomb structure. A sandwich honeycomb structure typically has a honeycomb structure.
    [0004] [0004] With this type of structure, a desired level of resistance to bending can be obtained with a lower density, compared to a structure that uses a solid core or a composite of a solid panel. The lower density can result in a desired weight reduction for an aircraft.
    [0005] [0005] These sandwich honeycomb structures, however, cannot withstand loads in a desired manner when loads are applied to one of the coatings of these sandwich honeycomb structures. One way in which additional load carrying capacity can be provided for a sandwich honeycomb structure is through the use of a potted core.
    [0006] [0006] Potting of an alveolar core is a process in which open areas open alveolar areas are filled with a material. This material can be a potting material or compound, such as a resin.
    [0007] [0007] The introduction of a filling material in an alveolar core, however, can take longer than desired. For example, a potting material can be placed inside the core and cured. Additional potting material is placed inside the core and cured. Then, the excess material can be removed by sandblasting, machining, or other processes. In some cases, additional material may be introduced after sandblasting or machining.
    [0008] [0008] This type of process can be more time-consuming and expensive than desired. In addition, the use of a filling material can also result in more weight than desired. Therefore, it would be desirable to have a method and apparatus that takes into account at least some of the problems discussed above, as well as other possible problems. SUMMARY
    [0009] [0009] In an illustrative embodiment, an apparatus comprises a first number of parts and a second number of parts. The first number of parts is configured to receive a charge. The second number of parts is configured to be assembled with the first number of parts to form a structural insert for a sandwich structure.
    [0010] [00010] In another illustrative embodiment, a honeycomb panel comprises a first coating, a second coating, a honeycomb core, and a structural insert. The honeycomb core is positioned between the first coating and the second coating. The structural insert is positioned in an alveolar cavity. The structural insert has a first number of parts configured to receive a load and a second number of parts.
    [0011] [00011] In additionally another illustrative embodiment, a method for making a sandwich structure is provided. A cavity is formed in a core of the sandwich structure. A structural insert is placed inside the cavity. The structural insert comprises a first number of parts configured to receive a load and a second number of parts is assembled with the first number of parts to form the structural insert.
    [0012] [00012] In additionally another illustrative embodiment, a method for handling a cargo on an aircraft is provided. The load is received in a honeycomb panel. The honeycomb panel comprises a first coating, a second coating, a honeycomb core, and a structural insert. The honeycomb core is positioned between the first coating and the second coating. The structural insert is positioned in an alveolar cavity. The structural insert has a first number of parts configured to receive the load and a second number of parts. The load is spread across the first number of parts in the structural insert.
    [0013] [00013] The characteristics and functions can be obtained independently in the various embodiments of the present description or can be combined in additionally other embodiments in which other details can be seen with reference to the following description and the following drawings. BRIEF DESCRIPTION OF THE DRAWINGS
    [0014] [00014] The features believed to be new to the illustrative embodiments are described in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, other purposes and characteristics thereof, will be better understood with reference to the following detailed description of an illustrative embodiment of the present description, when read in conjunction with the drawings annexes, in which: Figure 1 is an illustration of an aircraft according to an illustrative embodiment; Figure 2 is a more detailed illustration of a section of a floor on an aircraft according to an illustrative embodiment; Figure 3 is an illustration of a sandwich honeycomb structure according to an illustrative embodiment; Figure 4 is an illustration of a cross-sectional view of a sandwich structure according to an illustrative embodiment; Figure 5 is an illustration of an exploded view of a sandwich structure according to an illustrative embodiment; Figure 6 is an illustration of a sandwich structure with a structural insert according to an illustrative embodiment; Figure 7 is an illustration of a cross-sectional view of a sandwich structure according to an illustrative embodiment; Figure 8 is an illustration of an exploded view of a sandwich structure according to an illustrative embodiment; Figure 9 is an illustration of a sandwich structure with a structural insert according to an illustrative embodiment; Figure 10 is an illustration of a cross-sectional view of a sandwich structure according to an illustrative embodiment; Figure 11 is an illustration of an exploded view of a sandwich structure according to an illustrative embodiment; Figure 12 is an illustration of a sandwich structure with a structural insert according to an illustrative embodiment; Figure 13 is an illustration of a cross-sectional view of a sandwich structure according to an illustrative embodiment; Figure 14 is an illustration of an exploded view of a sandwich structure according to an illustrative embodiment; Figure 15 is an illustration of a sandwich structure with a structural insert according to an illustrative embodiment; Figure 16 is an illustration of a cross-sectional view of a sandwich structure according to an illustrative embodiment; Figure 17 is an illustration of an exploded view of a sandwich structure according to an illustrative embodiment; Figure 18 is an illustration of a sandwich structure with a structural insert according to an illustrative embodiment; Figure 19 is an illustration of a cross-sectional view of a sandwich structure according to an illustrative embodiment; Figure 20 is an illustration of an exploded view of a sandwich structure according to an illustrative embodiment; Figure 21 is an illustration of a block diagram of a structural sandwich environment according to an illustrative embodiment; Figure 22 is an illustration of a flowchart of a process for making a sandwich structure according to an illustrative embodiment; Figure 23 is an illustration of a flow diagram of a process for designing a sandwich structure according to an illustrative embodiment; Figure 24 is an illustration of a flow chart of a process for handling a cargo on an aircraft in accordance with an illustrative embodiment; Figure 25 is an illustration of a block diagram of an aircraft manufacturing and service method according to an illustrative embodiment; and Figure 26 is an illustration of an aircraft block diagram in which an illustrative embodiment can be implemented. DETAILED DESCRIPTION
    [0015] [00015] Illustrative embodiments recognize and take into account one or more different considerations. For example, the illustrative embodiments recognize and take into account that an alternative for filling the honeycomb structure with a resin, such as potting, may be the use of the inserts. For example, the illustrative embodiments recognize and take into account that a composite insert can be placed within an area of a honeycomb sandwich panel to receive a load.
    [0016] [00016] The illustrative embodiments recognize and take into account, however, that with the use of a solid insect, the amount of weight of the honeycomb sandwich panel may be greater than desired. This situation can reduce fuel efficiency for an aircraft's performance.
    [0017] [00017] The illustrative embodiments recognize and take into account that with the use of rapid prototyping systems, a customized structural insert can be designed and manufactured for use in an alveolar sandwich panel that results in less weight. For example, different parts can be manufactured using an additive manufacturing process. These parts can be assembled to form the structural inserts that receive a load in a desired manner for the honeycomb sandwich panel. This type of process is more accurate compared to portions of filling a honeycomb structure with a resin or other type of potting material.
    [0018] [00018] Thus, in an illustrative embodiment, an apparatus comprises a first number of parts configured to receive a load and a second number of parts configured to be assembled with the first number of parts to form a structural insert for a structure in sandwich.
    [0019] [00019] With reference now to the Figures, and in particular, with reference to Figure 1, an illustration of an aircraft is represented according to an illustrative embodiment. In this illustrative example, aircraft 100 has wing 102 and wing 104 attached to body 106. Aircraft 100 includes an engine 108 attached to wing 102 and an engine 110 attached to wing 104.
    [0020] [00020] Body 106 has nose section 112 and tail section 114. Horizontal stabilizer 116, horizontal stabilizer 118, and vertical stabilizer 120 are affixed to tail section 114 of body 106.
    [0021] [00021] Aircraft 100 is an example of an aircraft in which a sandwich structure can be implemented in accordance with an illustrative embodiment. For example, an illustrative embodiment can be implemented inside 122 of aircraft 100. For example, sandwich structures can be implemented in various parts, such as cabinet 124, wall 126, and floor 128, as well as in other parts or components that may be present inside interior 122 of aircraft 100. A more detailed illustration of section 130 of floor 128 is described below.
    [0022] [00022] The illustration of the aircraft 100 is not intended to limit the way in which the different illustrative embodiments can be implemented. For example, an illustrative embodiment can be implemented on different platforms than on an aircraft 100. The platform can be, for example, a mobile platform, a stationary platform, a land-based structure, a water-based structure, and a space-based structure. More specifically, the platform can be a surface ship, a tank, a personnel carrier, a train, a space vehicle, a space station, a satellite, a submarine, an automobile, an energy installation, a bridge, a dike , a house, a manufacturing facility, a building, or some other appropriate type of platform.
    [0023] [00023] Referring next to Figure 2, a more detailed illustration of a section of a floor on an aircraft is represented according to an illustrative embodiment. As shown, a more detailed view of section 130 of floor 128 on aircraft 100 in Figure 1 is shown.
    [0024] [00024] In this illustrative example, the sandwich structure 200 takes the form of honeycomb sandwich panel 202. As shown in this example, honeycomb sandwich panel 202 is composed of first layer 204, second layer 206, and core 208.
    [0025] [00025] In the illustrative example, core 208 is positioned between first layer 204 and second layer 206. As shown, core 208 is affixed to first layer 204 and second layer 206.
    [0026] [00026] The first layer 204 forms the first coating 210 and the second layer 206 forms the second coating 212 for the honeycomb sandwich panel 202. The core 208 takes the form of the honeycomb core 214 in this particular example.
    [0027] [00027] As shown, the honeycomb sandwich panel 202 has hole 216. Hole 216 in the honeycomb sandwich panel 202 may receive a fastener (not shown) for attaching the honeycomb sandwich panel 202 to another structure (not shown) on aircraft 100. This display may result in a load being applied to the honeycomb sandwich panel 202 during operation of aircraft 100.
    [0028] [00028] Going back to Figure 3, an illustration of a sandwich honeycomb structure is represented according to an illustrative embodiment. As shown, a described view of the sandwich structure 200 is shown. In this view, the second layer 206 has been removed from the view.
    [0029] [00029] As can be seen in this view, structural insert 300 is positioned in cavity 302 of core 208 in sandwich structure 200. Cavity 302 is configured to receive structural insert 300.
    [0030] [00030] As shown, structural insert 300 has a circular cross section and is composed of the first number of parts 304 and the second number of parts 306. The second number of parts 306 is configured to be assembled with the first number of parts 304 for form structural insert 300 in sandwich structure 200. When used here, "a number of", used with reference to items, means one or more items. For example, the first number of parts 304 means one or more parts.
    [0031] [00031] In the illustrative example, structural insert 300 is configured to spread a load across a surface of structural insert 300. For example, the load can be spread across surface 308 of the first layer 204 on the sandwich structure 200. As shown , the first number of parts 304 in structural insert 300 is configured to receive the load. Without structural insert 300, the configuration of the sandwich structure 200 may be less efficient with respect to spreading a load across the surface 308 of the sandwich structure 200.
    [0032] [00032] In these illustrative examples, the first number of parts 304, second number of parts 306, or both, can be manufactured using an additive manufacturing process. The additive manufacturing process can be, for example, three-dimensional printing. A design of an object made using software, such as a computer aided design program (CAD) or some other appropriate software, can then be used to print the object.
    [0033] [00033] In this particular example, the first number of parts 304 has a shape that is configured to spread a load applied to a structural insert 300. For example, the load can be applied in the direction of arrow 310, which is substantially perpendicular to the core. 208. The load can be spread in the direction of arrow 312 in the illustrative example. In other illustrative examples, the load can be applied from the opposite side, shown with respect to arrow 310. In other illustrative examples, the load can be applied in directions other than that with respect to arrow 310.
    [0034] [00034] Going back to Figure 4, an illustration of a cross-sectional view of a sandwich structure is shown according to an illustrative embodiment. A cross-sectional view of sandwich structure 200 is seen, taken along lines 4-4 in Figure 3.
    [0035] [00035] In this view, the first number of parts 304 includes part 400. The second number of parts 306 includes part 402 and part 404. In this illustrative example, part 400 fits between part 402 and part 404. Part 400, part 402, and part 404 are positioned in cavity 302 in core 208. For example, these parts can be placed within cavity 302 already assembled in the desired arrangement. In other illustrative examples, the parts can be assembled before being placed into cavity 302.
    [0036] [00036] Going back to Figure 5, an illustration of an exploded view of a sandwich structure is shown according to an illustrative embodiment. In this Figure, an exploded view of the sandwich structure 200 in Figure 2 is shown.
    [0037] [00037] As shown, the first layer 204 and the second layer 206 can be composed of aluminum. The honeycomb core 214 can be composed of fiberglass. The first number of parts 304 in structural insert 300 may be composed of graphite. The second number of parts 306 in the structural insert 300 can be composed of a composite material.
    [0038] [00038] As shown, first layer 204 has thickness 500, second layer 206 has thickness 502, and honeycomb core 214 has thickness 504. In this illustrative example, structural insert 300 has diameter 506 and thickness 508.
    [0039] [00039] In this illustrative example, these various dimensions may vary depending on the particular implementation. As shown, thickness 500 is about 0.1 inches (0.254 cm), thickness 502 is about 0.1 inches (0.254 cm), and thickness 504 is about 1.0 inches (2.54 cm) . Diameter 506 is about 3.0 inches (7.62 cm) and thickness 508 is about 1.0 inches (2.54 cm).
    [0040] [00040] With reference now to Figure 6, an illustration of a sandwich structure with a structural insert is shown according to an illustrative embodiment. In this illustrated example, a described view of the sandwich structure 600 is shown. The sandwich structure 600 is another illustrative example of a sandwich structure that can be used in section 130 of floor 128 on aircraft 100 in Figure 1.
    [0041] [00041] As shown in this described view, sandwich structure 600 includes first layer 602, core 604, and structural insert 606. A second layer for sandwich structure 600 is not shown in this described view.
    [0042] [00042] In this illustrative example, structural insert 606 is positioned in cavity 608 in core 604 of sandwich structure 600. As shown, structural insert 606 has an ellipsoidal cross section.
    [0043] [00043] The structural insert 606 is composed of the first number of parts 610 and the second number of parts 612. The first number of parts 610 is configured to receive a load that can be applied to the sandwich structure 600.
    [0044] [00044] Referring next to Figure 7, an illustration of a cross-sectional view of a sandwich structure is shown according to an illustrative embodiment. A cross-sectional view of sandwich structure 600 is seen, taken along lines 7-7 in Figure 6.
    [0045] [00045] In this view, the first number of parts 610 includes part 700. The second number of parts 612 includes part 702 and part 704.
    [0046] [00046] Going back to Figure 8, an illustration of an exploded view of a sandwich structure is shown according to an illustrative embodiment. In this Figure, an exploded view of the sandwich structure 600 in Figure 6 is shown.
    [0047] [00047] With reference now to Figure 9, an illustration of a sandwich structure with a structural insert is shown according to an illustrative embodiment. In this illustrated example, a described view of the sandwich structure 900 is shown. As shown, sandwich structure 900 is additionally another illustrative example of a sandwich structure that can be used in section 130 of floor 128 on aircraft 100 in Figure 1.
    [0048] [00048] In this described view, sandwich structure 900 includes first layer 902, core 904, and structural insert 906. The second layer for sandwich structure 900 is not shown in this described view.
    [0049] [00049] In this illustrative example, structural insert 906 is positioned in cavity 908 in core 904 of sandwich structure 900. As shown, structural insert 906 has a circular cross section.
    [0050] [00050] The structural insert 906 is composed of the first number of parts 910 and the second number of parts 912. The first number of parts 910 is configured to receive a load that can be applied to the sandwich structure 900.
    [0051] [00051] Referring next to Figure 10, an illustration of a cross-sectional view of a sandwich structure is shown according to an illustrative embodiment. A cross-sectional view of sandwich structure 900 is seen, taken along lines 10-10 in Figure 9.
    [0052] [00052] In this view, the first number of parts 910 includes part 1000. The second number of parts 912 includes part 1002. As shown, part 1000 is configured to be placed within part 1002. In this illustrative example, this assembly from part 1000 to part 1002 forms structural insert 906.
    [0053] [00053] Going back to Figure 11, an illustration of an exploded view of a sandwich structure is represented according to an illustrative embodiment. In this Figure, an exploded view of the sandwich structure 900 in Figure 9 is shown.
    [0054] [00054] Referring next to Figure 12, an illustration of a sandwich structure with a structural insert is shown according to an illustrative embodiment. In this illustrated example, a view of the sandwich structure 1200 is shown. As shown, sandwich structure 1200 is another illustrative example of a sandwich structure that can be used in section 130 of floor 128 on aircraft 100 in Figure 1.
    [0055] [00055] In this view, sandwich structure 1200 includes first layer 1202, core 1204, second layer 1206, and structural insert 1208. As shown, structural insert 1208 is positioned in cavity 1210 in core 1204 of the sandwich structure 1200. As shown, structural insert 1208 has a circular cross section.
    [0056] [00056] The structural insert 1208 is composed of the first number of parts 1212 and the second number of parts 1214. The first number of parts 1212 is configured to receive a load that can be applied to the sandwich structure 1200.
    [0057] [00057] In Figure 13, an illustration of a cross-sectional view of a sandwich structure is shown according to an illustrative embodiment. A cross-sectional view of sandwich structure 1200 is seen, taken along lines 13-13 in Figure 12.
    [0058] [00058] In this depicted view, the first number of parts 1212 includes part 1300. The second number of parts 1214 includes part 1302 and part 1304. As can be seen, part 1300 is configured to be placed between part 1302 and part 1304. For example, part 1300 can be placed over part 1302. Then, part 1304 can be placed over part 1302. This assembly of part 1304 and part 1302 is to hold part 1300 in place in the assembly that forms the 1208 structural insert.
    [0059] [00059] Returning to Figure 14, an illustration of an exploded view of a sandwich structure is represented according to an illustrative embodiment. In this Figure, an exploded view of the sandwich structure 1200 in Figure 12 is shown.
    [0060] [00060] Referring next to Figure 15, an illustration of a sandwich structure with a structural insert is shown according to an illustrative embodiment. In this depicted example, a described view of the sandwich structure 1500 is shown. The sandwich structure 1500 is another illustrative example of a sandwich structure that can be used in section 130 of floor 128 on aircraft 100 in Figure 1.
    [0061] [00061] As shown in this described view, sandwich structure 1500 includes first layer 1502, core 1504, and structural insert 1506. A second layer for sandwich structure 1500 is not shown in this described view.
    [0062] [00062] In this illustrative example, structural insert 1506 is positioned in cavity 1508 in core 1504 of sandwich structure 1500. As shown, structural insert 1506 has a square cross section.
    [0063] [00063] The structural insert 1506 is composed of the first number of parts 1510 and the second number of parts 1512. The first number of parts 1510 is configured to receive a load that can be applied to the sandwich structure 1500.
    [0064] [00064] With reference now to Figure 16, an illustration of a cross-sectional view of a sandwich structure is shown according to an illustrative embodiment. A cross-sectional view of sandwich structure 1500 is seen, taken along lines 16-16 in Figure 15.
    [0065] [00065] In this cross-sectional view, the first number of parts 1510 includes part 1600. The second number of parts 1512 includes part 1602, part 1604, part 1606, and part 1608.
    [0066] [00066] Going back to Figure 17, an illustration of an exploded view of a sandwich structure is shown according to an illustrative embodiment. In this Figure, an exploded view of the sandwich structure 1500 in Figure 15 is shown.
    [0067] [00067] With reference now to Figure 18, an illustration of a sandwich structure with a structural insert is shown according to an illustrative embodiment. In this illustrated example, a described view of the sandwich structure 1800 is shown. As shown, the sandwich structure 1800 is additionally another illustrative example of a sandwich structure that can be used in section 130 of floor 128 on aircraft 100 in Figure 1.
    [0068] [00068] In this described view, sandwich structure 1800 includes first layer 1802, core 1804, and structural insert 1806. The second layer for sandwich structure 1800 is not shown in this described view.
    [0069] [00069] In this illustrative example, structural insert 1806 is positioned in cavity 1808 in core 1804 of sandwich structure 1800. As shown, structural insert 1806 has a circular cross section.
    [0070] [00070] The structural insert 1806 is composed of the first number of parts 1810 and the second number of parts 1812. The first number of parts 1810 is configured to receive a load that can be applied to the sandwich structure 1800.
    [0071] [00071] As shown, the first number of parts 1810 has a shape that is configured to spread a load applied to structural insect 1806. For example, the load can be applied in the direction of arrow 1814 in the center 1816 of structural insert 1806, which it is substantially perpendicular to the core 1804. The charge can be spread in the direction of arrow 1818 in the illustrative example.
    [0072] [00072] In this illustrative example, the load is at a maximum close to the center 1816 of structural insert 1806 and can then decrease in the direction of arrow 1818 from central point 1819. Similarly, the first number of parts 1810 has a shape that decreases in thickness in the direction of arrow 1818. The shape of the first number of parts 1810, therefore, provides the maximum structural support close to the center 1816 of structural insert 1806 where the load is at a maximum and there is less structural support, since the thickness of the first number of parts 1810 decreases in the direction of arrow 1818. The shape of the first number of parts 1810 can provide a high reduction in weight, while additionally providing sufficient structural support.
    [0073] [00073] Additionally, the first number of parts 1810 can have part 1820 and part 1822. Part 1820 and part. 1822 are semicircular cutouts, in this example shown. In other illustrative examples, part 1820 and part 1822 may have a shape selected from one of a parabola, a triangle, an arc, or other shapes. Part 1820 and part. 1822 removes material from the first number of parts 1810 which may not need to distribute the load applied to structural insect 1806. In this way, the density of the first number of parts 1810 is changed to create a configuration that results in reduced weight of the structural insert 1806. In other illustrative examples, the density of the first number of parts 1810 can be changed by drilling holes, removing material, combining different materials, or other techniques.
    [0074] [00074] Referring next to Figure 19, an illustration of a cross-sectional view of a sandwich structure is shown according to an illustrative embodiment. A cross-sectional view of sandwich structure 1800 is seen, taken along lines 19-19 in Figure 18.
    [0075] [00075] In this view, the first number of parts 1810 includes part 1900. The second number of parts 1812 includes part 1902 and part 1904.
    [0076] [00076] Going back to Figure 20, an illustration of an exploded view of a sandwich structure is shown according to an illustrative embodiment. In this Figure, an exploded view of the sandwich structure 1800 in Figure 18 is shown.
    [0077] [00077] The different illustrations of a sandwich structure with a structural insert in Figures 2-17 are only presented as illustrative examples of some implementations for a sandwich structure and a structural insert. These illustrations are not intended to limit the way in which other illustrative embodiments can be implemented.
    [0078] [00078] For example, although the sandwich structure has been represented as having a first layer and a second layer with a core between the layers, the sandwich structure can have other configurations. For example, two layers can be present on either side of the core, instead of just one layer, as shown. Additionally, the layers can be formed from the same type of material or different types of materials. In other words, the first layer can be composed of the same material as the second layer or different materials than the second layer.
    [0079] [00079] As another example, although the sandwich structures are shown to be flat, the sandwich structures can have other shapes. For example, sandwich structures can be curved, rather than flat, as shown in these illustrative examples.
    [0080] [00080] In a further illustrative example, one or more structural inserts can be used in addition to the structural inserts in the different illustrations. In addition, although the structural insert is shown to be centrally positioned in the sandwich structure, the structural inserts can be placed elsewhere in the sandwich structure.
    [0081] [00081] Additionally, the different structural inserts can have different shapes from those shown. For example, structural inserts can have an excitable cross section, an irregular cross section, or some other suitable shape. In addition to other illustrative examples, the structural inserts may have another shape, such as a sphere, a cone trunk, or other types of volumes.
    [0082] [00082] With reference now to Figure 21, an illustration of a block diagram of a structural sandwich design environment is represented according to an illustrative embodiment. As shown, the structural sandwich production environment 2100 is configured to generate design 2102 for sandwich structure 2104 and can also be used to manufacture sandwich structure 2104.
    [0083] [00083] In the illustrative example, designer 2106 is configured to generate project 2102 and can be implemented in software, hardware, firmware or a combination thereof. When software is used, the operations performed by the designer 2106 can be implemented in program code configured to run on a processor unit. When firmware is used, the operations performed by the 2106 designer can be implemented in program code and data and stored in persistent memory to run on a processor unit. When hardware is employed, the hardware can include circuits that operate to perform operations on the 2106 designer.
    [0084] [00084] In the illustrative examples, the hardware can take the form of a circuit system, an integrated circuit, an application-specific integrated circuit (ASIC), a programmable logic device, or some other appropriate type of hardware configured to run a number operations. With a programmable logic device, the device can be configured to perform the number of operations. The device can be reconfigured at a later time or it can be permanently configured to perform the number of operations. Examples of programmable logic devices include, for example, a programmable logic arrangement, a programmable arrangement logic, a field programmable logic arrangement, a field programmable gate arrangement, and other appropriate hardware devices. Additionally, the processes can be implemented in organic components integrated with organic components and / or can be composed entirely of organic components that exclude a human being. For example, processes can be implemented as circuits in organic semiconductors.
    [0085] [00085] In this illustrative example, designer 2106 is positioned on computer system 2108. Computer system 2108 is made up of a number of computers. When more than one computer is present in computer system 2108, those computers can communicate with each other through a communication medium, such as a network.
    [0086] [00086] As depicted, designer 2106 can receive input 2110 for use in generating project 2102 for sandwich structure 2104. For example, input 2110 can include input parameters 2112. Input parameters 2112 can describe, for example, load 2114, weight 2116, and other appropriate parameters.
    [0087] [00087] In the illustrative example, load 2114 is one or more forces, formations, accelerations, or some combination thereof, applied to sandwich structure 2104. Load 2114 can be caused by another structure. Input parameters 2112 for load 2114 may include a direction of the force, the magnitude of the force, and other appropriate factors. The direction of the force can, for example, describe at least one of the spreading or the desired spreading of the force on sandwich structure 2104.
    [0088] [00088] Using input 2110, designer 2106 is configured to generate design 2102. In particular, designer 2106 can generate design parameters 2118 for sandwich structure 2104.
    [0089] [00089] As shown, the design parameters 2118 can include several parameters. For example, design parameters 2118 may describe components 2120 in sandwich structure 2104. Components 2120 may include, for example, at least one of first layer 2122, second layer 2124, core 2126, and structural insert 2128 in the sandwich structure 2104.
    [0090] [00090] In the illustrative example, design parameters 2118 can include at least one of dimensions 2130, materials 2132, location 2133, or other appropriate parameters to describe the various components in sandwich structure 2104.
    [0091] [00091] For example, dimensions 2130 and materials 2132 can be used to customize structural insert 2128 in a way that satisfies the weight 2116 that can be desired for sandwich structure 2104 to support load 2114, as specified in entry 2110 For example, dimensions 2130 and materials 2132 can be used to describe the first number of parts 2134 and the second number of parts 2136 in structural insert 2128.
    [0092] [00092] In the illustrative examples, dimensions 2130 can take various forms. Such forms may include those for the illustrative examples shown in Figures 2-21.
    [0093] [00093] Materials 2132 for the first number of parts 2134 and the second number of parts 2136 can be composed of a number of materials selected from at least one of a composite material, a metal, aluminum, titanium, graphite, plastic, polycarbonate, glass, fiberglass, wood, concrete, steel, carbon fiber, synthetic para-aramid fiber, a carbon fiber reinforced thermoplastic, a carbon fiber thermostable polymer, or other suitable materials. Material selection 2132 can also be used to generate density 2138 for at least one of the first number of parts 2134 or the second number of parts 2136.
    [0094] [00094] Dimensions 2130 can also include hole identification or other characteristics that can be used to change density 2138 to at least one of the first number of parts 2134 or the second number of parts 2136. For example, dimensions 2130 can include identifying holes, voids, or other characteristics that may be desirable to change the density 2138. As a result, the density 2138 for the first number of parts 2134 may be different over different portions of the first number of parts 2134 based on load expected to be placed on or received by structural insert 2128, as specified by load 2114 at entry 2110.
    [0095] [00095] Changes or density selection 2138 for different parts of structural insert 2128 can be used to achieve weight 2116 for load 2114 at a specified entry 2110. In this way, weight savings can be achieved while handling in processing of loads in a desired manner is provided.
    [0096] [00096] Additionally, dimensions 2130 and materials 2132 can also describe at least one of the first layer 2122, the second layer 2124, or core 2126. In the illustrative examples, the first layer 2122 and the second layer 2124 can be a number of laminate layers comprising materials selected from at least one of steel, aluminum, a composite material, fiberglass, or carbon fiber.
    [0097] [00097] In these illustrative examples, materials 2132 for at least one of the first layer 2122 or the second layer 2124 can be selected from at least one of steel, aluminum, a composite material, fiberglass, or carbon fiber.
    [0098] [00098] The 2132 materials for the 2126 core can be selected from at least one of fiberglass, paper, cardboard, wood, foam, steel, a composite material, a resin infused with carbon fiber, or other appropriate materials . The selected material can be based on the type of core used for the 2126 core. For example, the 2126 core can be selected from one of a foam core, a honeycomb core, a composite core, or some other appropriate type of core.
    [0099] [00099] In this illustrative example, location 2133 describes the location of structural insert 2128 in sandwich structure 2104. Location 2133 can be identified from entry 2110. For example, load 2114 can describe the location where a force can be applied to sandwich structure 2104. The force location can be used to identify location 2133 for structural insert 2128.
    [0100] [000100] With design 2102, designer 2106 can run simulation 2140 for sandwich structure 2104. Based on simulation results 2140, adjustments can be made to design 2102, when necessary, to achieve or satisfy input parameters 2112 at entry 2110.
    [0101] [000101] Additionally, the design 2102 can be used by the 2142 fabrication system to manufacture the sandwich structure 2104. In particular, at least one of the first number of parts 2134 or second number of parts 2136 can be manufactured using fabrication equipment. additive 2144 in the 2142 manufacturing system.
    [0102] [000102] With the first layer 2122, the second layer 2124, the core 2126, the first number of parts 2134 and the second number of parts 2136, the operator 2146 can mount the sandwich structure 2104. The operator 2146 can be, for example , a human operator or a robotic operator.
    [0103] [000103] The illustration of the 2100 structural sandwich production environment in Figure 21 is not intended to imply physical or architectural limitations to the way in which an illustrative embodiment can be implemented. Other components in addition to, or in place of, those illustrated, may be used. Some components may be unnecessary. Also, the blocks are presented to illustrate some functional components. One or more of these blocks can be combined, divided, or combined and divided into different blocks, when implemented in an illustrative embodiment.
    [0104] [000104] For example, other types of manufacturing equipment can be used in place of, or in addition to, additive manufacturing equipment 2144. For example, molding equipment, composite manufacturing equipment, lathes, water jets , lasers, and other appropriate types of equipment can be used to manufacture the first number of parts 2134 and the second number of parts 2136 in structural insert 2128.
    [0105] [000105] Additionally, the different components shown in Figures 1-17 can be combined with components in Figure 21, used with the components in Figure 21, or a combination of the two. In addition, some of the components in Figures 1-17 can be illustrative examples of how the components shown in the form of blocks in Figure 21 can be implemented as physical structures.
    [0106] [000106] Referring next to Figure 22, an illustration of a flowchart of a process for manufacturing a sandwich structure is represented according to an illustrative embodiment. The process illustrated in Figure 22 can be implemented in the structural sandwich production environment 2100 in Figure 21. In particular, one or more of the different operations can be implemented using the 2142 manufacturing system or some other appropriate components. The sandwich structure can be manufactured for use on a platform, such as aircraft 100 in Figure 1 as well as other platforms.
    [0107] [000107] The process starts by affixing a first layer to a sandwich structure (operation 2200). The process then forms a cavity in a core of the sandwich structure (operation 2202). Then, a structural insert is placed inside the cavity (operation 2204).
    [0108] [000108] The second layer is then affixed to at least one of the core or the structural insert after placing the structural insert into the cavity (operation 2206), with the process ending afterwards.
    [0109] [000109] Referring next to Figure 23, an illustration of a flowchart of a process for designing a sandwich structure is represented according to an illustrative embodiment. The process illustrated in this flowchart can be implemented on designer 2106 in Figure 21 in an illustrative example. The process can be used to generate the 2102 design for sandwich structure 2104 in the illustrative example.
    [0110] [000110] The process starts by receiving input for a sandwich structure (operation 2300). The process identifies the input parameters from the input to the sandwich structure (operation 2302). Input parameters can include, for example, a load that can be applied to the sandwich structure. The input parameters describing the load can describe the direction and magnitude of the load. In addition, the parameters can also specify a desired weight for the sandwich structure for the components in the sandwich structure.
    [0111] [000111] The process then generates design parameters for the sandwich structure (operation 2304). Design parameters can include, for example, dimensions, materials, and other parameters for sandwich structures. In particular, these parameters can describe components, such as a first layer, a second layer, a core, and a structural insert in the sandwich structure. The process then stores the design parameters in a drawing (operation 2306).
    [0112] [000112] The simulation is then run using the project (operation 2308). Then, the determination is made as to whether the design parameters in the project satisfy the input parameters (operation 2310). If the design parameters in the project satisfy the input parameters, the process ends. otherwise, adjustments are made to the design parameters (operation 2312), with the process then returning to operation 2308.
    [0113] [000113] Now returning to Figure 24, an illustration of a flowchart of a process for handling a cargo on an aircraft is represented according to an illustrative embodiment. The process illustrated in Figure 24 can be implemented on a sandwich structure, such as a honeycomb panel, on an aircraft, such as aircraft 100 in Figure 1.
    [0114] [000114] The process starts by receiving a load on a honeycomb panel (operation 2400). In this illustrative example, the honeycomb panel comprises a first coating, a second coating, a honeycomb core positioned between the first coating and the second coating, and a structural insert positioned in a honeycomb cavity. The structural insert has a first number of parts configured to receive the load and a second number of parts.
    [0115] [000115] The process then spreads the load through a first number of parts in a structural insert (operation 2402), with the process turned over. In the illustrative example, the charge can be spread across the first number of parts so that the charge spreads through the honeycomb panel lining. The coating can be the first coating or the second coating on either side of a core in the illustrative example.
    [0116] [000116] Flowcharts and block diagrams in the different embodiments illustrate the architecture, functionality, and operation of some possible implementations of devices and methods in an illustrative embodiment. In this regard, each block in the flowcharts or block diagrams can represent a module, segment, function, and / or a portion of an operation or step. For example, one or more of the blocks can be implemented as program code, in hardware, or a combination of program code and hardware. When implemented in hardware, the hardware can, for example, take the form of integrated circuits that are manufactured or configured to perform one or more operations in flowcharts or block diagrams. When implemented as a combination of program code and hardware, the implementation can take the form of firmware.
    [0117] [000117] In some alternative implementations of an illustrative embodiment, the function or functions noted in the blocks may occur out of the order noted in the Figures. For example, in some cases, two blocks shown in succession can be executed substantially simultaneously, or the blocks can sometimes be performed in reverse order, depending on the functionality involved. Also, other blocks can be added in addition to the blocks illustrated in a flow chart or block diagram.
    [0118] [000118] For example, the cavity formed in operation 2202 can be performed before, or after, fixing the core to the first layer in operation 2200. As another example, the process for generating and designing a honeycomb structure can also include operations in what simulations performed on the adjustments are made to the project based on how the simulation results work.
    [0119] [000119] Illustrative embodiments of the description can be described in the context of the aircraft manufacturing and service method 2500, as shown in Figure 25, and the 2600 aircraft as shown in Figure 26. Returning first to Figure 25, an illustration of a block diagram of an aircraft manufacturing and service method is represented according to an illustrative embodiment. During pre-production, the 2500 aircraft manufacturing and service method may include specification and design 2502 for aircraft 2600 in Figure 26 and the acquisition of material 2504.
    [0120] [000120] During production, the manufacture of components and subassemblies 2506 and the integration of systems 2508 of the aircraft 2600 in Figure 26 takes place. Then, aircraft 2600 in Figure 26 can pass through certification and supply 2510 in order to be placed in service 2512. While in service 2512 by a customer, aircraft 2600 in Figure 26 is scheduled for routine maintenance and service 2514, which may include modification, reconfiguration, remodeling, and other maintenance or service.
    [0121] [000121] Each of the 2500 aircraft manufacturing and service method processes can be performed or performed by a system integrator, a third party, and / or an operator. In these examples, the operator can be a customer. For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and subcontractors to the main system; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator can be an airline company, a leasing company, a military organization, a service organization, and others.
    [0122] [000122] With reference now to Figure 26, an illustration of an aircraft block diagram is shown, in which an illustrative embodiment can be implemented. In this example, the 2600 aircraft is produced by the 2500 aircraft manufacturing and service method in Figure 25 and can include the fuselage 2602 with a plurality of systems 2604 and interior 2606. Examples of the 2604 systems include one or more of the 2608 propulsion system, electric 2610, hydraulic system 2612, and environmental system 2614. Any number of other systems can be included. Although an aerospace example is shown, different illustrative embodiments can be applied to other industries, such as the automotive industry.
    [0123] [000123] The apparatus and methods incorporated here can be used during at least one of the stages of the aircraft manufacturing and service method 2500 in Figure 25. For example, a sandwich structure with a structural insert according to an illustrative embodiment can be manufactured during the manufacture of components and subassemblies 2506. The sandwich structure can be implemented on the 2600 aircraft during the integration of 2508 systems. Additionally, the sandwich structure with a structural insert according to an illustrative embodiment can be implemented on aircraft 2600 during maintenance and service 2514. For example, a sandwich structure can be used to replace other sandwich structures during routine maintenance, remodeling, upgrades, or other operations performed during maintenance and service 2514. As another example, the use of a sandwich structure with a structural insert according to a form of realization illustrative use on aircraft 2600 while aircraft 2600 is in service 2512 can reduce operating expenses for the aircraft. For example, the reduction in weight can reduce fuel costs and can increase the performance of the 2600 aircraft.
    [0124] [000124] One or more device embodiments, method embodiments, or a combination thereof can be used while the 2600 aircraft is in service 2512 and / or during maintenance and service 2514, in Figure 25. The use a number of the different illustrative embodiments can substantially accelerate the assembly of, and / or reduce the cost of, the 2600 aircraft.
    [0125] [000125] Thus, one or more of the illustrative embodiments provides a method and apparatus for a sandwich structure to support a load. In an illustrative embodiment, the sandwich structure includes a structural insert configured to spread the load across the surface of the sandwich structure.
    [0126] [000126] In the illustrative examples, the structural insert is composed of days or more parts. The first number of parts is configured to receive a charge. This first number of parts is also configured to spread the load. The second number of parts is configured to be assembled with the first number of parts to form the structural inserts.
    [0127] [000127] In the illustrative examples, the different parts in the structural inserts can have a density that varies. The density can vary based on the type of material used, the density of holes, removal of material from areas in which a lower density is desired, or other appropriate techniques. In this way, the desired handling of a load can be achieved while reducing the weight of the sandwich structure.
    [0128] [000128] The description of the different illustrative embodiments has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments in the manner described. Many modifications and variations will be apparent to those of ordinary skill in the art. In addition, different illustrative embodiments may provide different characteristics compared to other illustrative embodiments. The selected embodiment or embodiments are chosen and described to better explain the principles of the embodiments, the practical application, and to allow others of ordinary skill in the art to understand the description for the various embodiments with various modifications as are appropriate for the particular intended use. In addition, the description comprises embodiments in accordance with the following clauses:
    [0129] [000129] Clause 1. A honeycomb panel comprising: a first coating (210); a second coating (212); a honeycomb core (214) positioned between the first coating (210) and the second coating (212); and a structural insert (2128) positioned in a cavity (302) open alveolar areas (214), in which the structural insert (2128) has a first number of parts (2134) configured to receive a load (2114) and a second number of parts (2136).
    [0130] [000130] Clause 2. The honeycomb panel according to clause 1, in which the structural insert (2128) is manufactured using an additive manufacturing process.
    [0131] [000131] Clause 3. The honeycomb panel according to clause 1, in which the density (2138) of the first number of parts (2134) is different over different portions of the first number of parts (2134) based on the load (2114) ) expected.
    [0132] [000132] Clause 4. A method for handling a cargo (2114) on an aircraft, the method comprising: receiving (2400) the charge (2114) in a honeycomb panel comprising a first coating (210), a second coating (212), a honeycomb core (214) positioned between the first coating (210) and the second coating (212), and a structural insert (2128) positioned in a cavity (302) open alveolar areas (214), in which the structural insert (2128) has a first number of parts (2134) configured to receive the load (2114) and a second number parts (2136); and spreading (2402) the charge (2114) through the first number of parts (2134) in the structural insert (2128).
    [0133] [000133] Clause 5. A method for making a sandwich structure (2104), the method comprising: forming (2202) a cavity (302) in a core (2126) of the sandwich structure (2104); and placing (2204) a structural insert (2128) into the cavity (302), wherein the structural insert (2128) comprises a first number of parts (2134) configured to receive a load (2114) and a second number of parts (2136) ) assembled with the first number of parts (2134) to form the structural insert (2128).
    [0134] [000134] Clause 6. The method according to clause 5, in which the sandwich structure (2104) is a honeycomb sandwich panel (202) and the honeycomb sandwich panel (202) is positioned in the selected structure from one of the a floor (128), the cabinet (124), and a wall (126).
    权利要求:
    Claims (15)
    [0001]
    Apparatus, characterized by the fact that it comprises: a plurality of first parts (2134) and a second part (2136), the plurality of first parts and second part configured to fit entirely within a cavity (302) in a sandwich structure (2104); wherein the second part comprises at least one longitudinal element having a hole in it and is configured to engage the first plurality of parts within the cavity (302) of the sandwich structure (2104) to form a structural insert (2128) in the structure in sandwich (2104), wherein the second part (2136) extends across a diameter of the cavity (302) dividing the plurality of first parts (2134) into two sections; wherein the sandwich structure (2104) comprises a first layer (2122) having a first opening, a second layer (2124) having a second opening, and a core (2126) having the cavity (302) therein, configured to contain the structural insert (2128) so that the first opening, the hole, and the second opening provide a passage through the sandwich structure (2104); wherein the cavity (302) is substantially circular or oval.
    [0002]
    Apparatus according to claim 1, characterized in that the structural insert (2128) is configured to spread a load (2114) across a surface (308) of the sandwich structure (2104).
    [0003]
    Apparatus according to claim 1, characterized in that the core (2126) is selected from one of a foam core, a honeycomb core, or a composite core.
    [0004]
    Apparatus according to claim 1, characterized by the fact that the structural insert (2128) is manufactured using an additive manufacturing process.
    [0005]
    Apparatus according to claim 1, characterized in that a density (2138) for the first plurality of parts (2134) is different over different portions of the first plurality of parts (2134) based on an expected charge (2114).
    [0006]
    Apparatus according to claim 1, characterized by the fact that the sandwich structure (2104) is a honeycomb sandwich panel (202) and the honeycomb sandwich panel (202) is located in a structure selected from one of a floor ( 128), the cabinet (124), and a wall (126).
    [0007]
    Apparatus according to claim 1, characterized in that the first layer (2122) and the second layer (2124) are a number of layers of laminate comprising materials selected from at least one of steel, aluminum, a composite material, fiber glass, or carbon fiber.
    [0008]
    Apparatus according to claim 1, characterized in that the first plurality of parts (2134) and the second plurality of parts (2136) are comprised of a number of materials selected from at least one of a composite material, a metal, aluminum, titanium, graphite, plastic, polycarbonate, glass, fiberglass, wood, concrete, steel, carbon fiber, synthetic para-aramid fiber, a carbon fiber reinforced thermoplastic, or a carbon fiber thermostable polymer.
    [0009]
    Apparatus according to claim 1, characterized by the fact that the sandwich structure (2104) is located on a platform selected from one of a mobile platform, a stationary platform, a land-based structure, a water-based structure, a space-based structure, an aircraft, a ship surface (308), a tank, personnel carrier, a train, a space vehicle, a space station, a satellite, a submarine, an automobile, a power installation, a bridge , a dike, a house, a manufacturing facility, and a building.
    [0010]
    Method for fabricating a sandwich structure (2104), the method characterized by the fact that it comprises: forming (2202) a cavity (302) in a core (2126) of the sandwich structure (2104); placing (2204) a structural insert (2128) into the cavity (302) of a core (208); affixing (2126) the core to a first layer (2122) having a first opening; forming the cavity (302) in the core (208); and affixing (2206) a second layer (2124) having a second opening to at least one of the core or structural insert (2128) after placing the structural insert (2128) into the cavity (302); wherein the structural insert (2128) is configured to receive a load (2114) and to fit entirely within a core cavity, the structural insert (2128) comprises a plurality of first parts (2134) and a second part (2136) ) having at least one longitudinal element and a hole in it and configured to engage the plurality of first parts within the cavity (302) of the core, the second part (2136) extending across a diameter of the cavity (302) dividing the plurality of first parts (2134) into two sections; wherein the first opening, the hole, and the second opening define a passage completely through the first layer, the second layer, and the core; wherein the cavity is substantially circular or oval.
    [0011]
    Method according to claim 10, characterized in that it additionally comprises: identifying the anticipated load (2114) for the sandwich structure (2104); and projecting the plurality of first parts (2134) and the second plurality of parts (2136) so that the first plurality of parts (2134) receives the load (2114), when assembled, to form the structural insert (2128) within the structure sandwich (2104).
    [0012]
    Method according to claim 10, characterized in that the density (2138) of the first plurality of parts (2134) is different over different portions of the first plurality of parts (2134) based on the expected load (2114).
    [0013]
    Method according to claim 10, characterized in that the sandwich structure (2104) is a honeycomb sandwich panel (202) and the honeycomb sandwich panel (202) is located in a structure selected from one of a floor ( 128), the cabinet (124), and a wall (126)
    [0014]
    Method according to claim 10, characterized in that the core (2126) is selected from one of a foam core, a honeycomb core, or a composite core.
    [0015]
    Method according to claim 10, characterized in that the structural insert (2128) is manufactured using an additive manufacturing process.
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    同族专利:
    公开号 | 公开日
    RU2014129287A|2016-02-10|
    CA2859329C|2017-04-25|
    CA2859329A1|2015-03-03|
    US20150298423A1|2015-10-22|
    US9981446B2|2018-05-29|
    EP2875946A1|2015-05-27|
    BR102014020218B8|2020-09-08|
    CN104417745A|2015-03-18|
    JP2016001053A|2016-01-07|
    BR102014020218A2|2015-09-22|
    EP2875946B1|2021-04-21|
    JP6449588B2|2019-01-09|
    CN104417745B|2021-02-26|
    RU2671805C2|2018-11-06|
    KR102158884B1|2020-09-23|
    KR20150026819A|2015-03-11|
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    法律状态:
    2015-09-22| B03A| Publication of an application: publication of a patent application or of a certificate of addition of invention|
    2018-02-27| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2020-03-24| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-07-14| B09A| Decision: intention to grant|
    2020-08-25| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 14/08/2014, OBSERVADAS AS CONDICOES LEGAIS. |
    2020-09-08| B16C| Correction of notification of the grant|Free format text: REF. RPI 2590 DE 25/08/2020 QUANTO AO ENDERECO. |
    优先权:
    申请号 | 申请日 | 专利标题
    US14/016691|2013-09-03|
    US14/016,691|US9981446B2|2013-09-03|2013-09-03|Structural inserts for honeycomb structures|
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