3D Printed Fiber-Reinforced Linkage for Non-Cylindrical Structures
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Solution Overview
Problem
Existing composite tube assemblies in vehicles are limited to traditional cylindrical shapes, restricting their use in applications requiring non-traditional shapes, and there is a need for lighter and stronger linkages with improved structural support.
Innovation Solution
The development of 3D printed linkages using onyx plastics or nylons reinforced with continuous fibers, such as carbon fiber, Kevlar, or fiberglass, featuring non-traditional shapes and embedded inserts, which are 3D printed at angles to enhance strength and allow for non-circular cross-sections and angled orientations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If traditional composite tube assemblies with fittings are used, then the structure is strong and corrosion-resistant, but the shape is limited to cylindrical forms
Solution Approach 1:
The patent changes the manufacturing method from traditional composite tube assembly to 3D printing, enabling variable cross-sections and non-cylindrical shapes while maintaining structural integrity. This allows the linkage to adapt to different application requirements with customized geometries.
Solution Approach 2:
The patent uses composite materials (continuous fiber reinforcement in polymer matrix) in the 3D printed linkage, combining the strength and corrosion resistance of traditional composite tubes with the geometric flexibility of additive manufacturing to create linkages with non-traditional shapes.
2Strength
If 3D printed linkages with continuous fiber reinforcement are used, then tensile strength increases to at least 9000 lbf, but manufacturing complexity increases
Solution Approach 1:
The patent changes the material parameters by incorporating continuous fiber reinforcement (carbon fiber, Kevlar, or fiberglass) into the 3D printed polymer matrix, achieving tensile strength of at least 9000 lbf while maintaining the additive manufacturing process.
3Shape
If traditional composite tube assemblies are used, then the structure is lightweight, but the design is limited to standard cylindrical configurations
Solution Approach 1:
The patent changes the design parameters by using 3D printing technology that allows variable cross-sections and non-cylindrical configurations, enabling customized linkage shapes optimized for specific applications while maintaining the lightweight advantage of composite 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
The 3D printed linkages provide enhanced tensile, torsional, and shear strength, with axial strengths up to 13000 lbf, enabling versatile structural support in non-traditional configurations while maintaining lightweight properties.
Implementation Method 1
a body formed by 3D printing
Implementation Method 2
nylons reinforced with a continuous fiber... the continuous fiber is fiber selected from the group of fibers consisting essentially of carbon fiber, Kevlar, and fiberglass fibers
Data Source
AI summary
A 3D printed linkage includes a first end opposite a second end and a pin or insert proximate each end for connecting a connecting member thereto.