Composite Core Attachment Rail for Non-Parallel Support Members
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Solution Overview
Problem
The use of composite core materials in aerospace applications faces challenges in attaching to non-parallel surrounding support structures without adding weight, compromising structural stability, and limiting the passage of lines and hoses, while also posing environmental hazards due to fillers and additives.
Innovation Solution
A composite core assembly with integrated attachment rails, featuring a first planar surface parallel to the core structure and a second planar surface at an angle, allows for secure attachment to surrounding support members without additional weight, while maintaining structural integrity and enabling passage of lines and hoses through designed gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If fillers and additives are used to adhere composite core material to surrounding structure, then attachment is achieved, but weight increases and structural stability is compromised
Solution Approach 1:
The attachment rail is divided into two distinct planar surfaces: a first planar surface integrated with the composite core structure and a second planar surface arranged at an angle (e.g., 90 degrees) relative to the first. This segmentation allows each surface to be optimized for its specific function - the first surface for integration with the core and the second surface for attachment to surrounding support members at non-parallel orientations.
Solution Approach 2:
The invention transitions from a single-planar attachment approach to a multi-dimensional approach by introducing a second planar surface at an angle relative to the first. This angular configuration enables attachment to surrounding structures that are not parallel to the primary axes of the core, adding orientational dimensionality to the attachment capability.
2Strength
If fillers and additives are used to attach composite core, then attachment is achieved, but harmful chemicals are released to environment
Solution Approach 1:
The invention extracts and eliminates the need for fillers and chemical additives from the attachment process. By providing pre-formed attachment rails with planar surfaces that can be mechanically fastened or adhesively bonded without requiring filler materials, the harmful chemical byproducts associated with traditional filler-based attachment methods are removed entirely.
3Strength
If fillers and additives are used for attachment, then composite core is secured, but passage of lines and hoses is limited
Solution Approach 1:
The attachment rail is segmented into distinct planar surfaces with the second planar surface extending beyond the perimeter of the composite core structure. This segmentation creates accessible attachment points and pathways that do not enclose or block the passage of electrical lines, hoses, air lines, and fuel lines, allowing for inspection and repair while maintaining secure attachment.
Data Source
AI summary
A composite core assembly includes a composite core structure having internal material interfaces and an attachment rail coupled to the composite core structure. The attachment rail includes a first planar surface and a second planar surface adjoined with the first planar surface. The first planar surface is arranged parallel to an internal material interface plane of the composite core structure, and the first planar portion is at least partially integrated into the composite core structure in an internal material interface plane. At least a portion of the first planar surface extends beyond a perimeter surface of the composite core structure, and the second planar surface is configured to attach to the surrounding support member. The core material does not have net edge facets or flat edges positioned next to surrounding structure, and/or may not have a structure arranged parallel to the adjacent support structure to attach to the support structure.