Carbon Fiber Tube Coupling With Reciprocating Catches for Fast Assembly
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Solution Overview
Problem
Current methods for coupling carbon fiber composite structures require adhesives, welds, or complex and expensive fasteners, making them time-consuming and dependent on controlled environmental conditions for epoxy curing, which limits mass production and widespread adoption.
Innovation Solution
A universal coupling system using reciprocating catches that engages receiving features in carbon fiber structures, allowing for quick and secure attachment without adhesives or welding, and can be manufactured using conventional equipment, enabling rapid assembly and integration into various applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If epoxy and controlled environment curing is used to join carbon fiber structures, then strong permanent attachment is achieved, but production time increases and environmental control requirements increase complexity
Solution Approach 1:
The patent replaces the chemical epoxy bonding system with a mechanical fastening system using a coupling device that physically connects two carbon fiber structures through recesses and lugs. This mechanical substitution eliminates the need for epoxy application, curing time, and environmental control while achieving strong permanent attachment through mechanical interlocking.
Solution Approach 2:
The invention extracts the time-consuming epoxy curing process entirely from the manufacturing workflow by using a purely mechanical coupling mechanism. The coupling device with its recesses and lugs provides immediate structural connection without requiring chemical bonding or environmental-controlled curing periods.
2Strength
If epoxy and controlled environment curing is used to join carbon fiber structures, then strong permanent attachment is achieved, but process complexity and environmental control requirements increase
Solution Approach 1:
The patent replaces the complex chemical epoxy bonding process with a simple mechanical fastening system. The coupling device uses physical recesses and lugs that require no environmental control, temperature monitoring, or humidity management, thereby reducing process complexity while maintaining attachment strength.
Solution Approach 2:
The coupling device is designed to self-align and self-secure through its recess and lug geometry. The structure automatically positions itself during assembly without requiring precise environmental conditions or complex alignment procedures, making the process simpler and more forgiving.
3Productivity
If fasteners and sleeves are used to attach carbon fiber structures, then assembly speed increases, but cost and mechanism complexity increase
Solution Approach 1:
The patent creates a universal coupling device that can attach to various carbon fiber structure configurations through standardized recess and lug interfaces. This single multi-functional design replaces the need for multiple specialized fasteners and sleeves, simplifying the coupling mechanism while maintaining fast assembly speed across different applications.
Solution Approach 2:
The coupling device is segmented into distinct functional components: the main body with recesses for receiving structure features, and protruding lugs for positive engagement. This segmentation allows each component to perform its specific function efficiently, achieving fast assembly without requiring complex integrated mechanisms.
4Productivity
If expanding inserts are used to fasten carbon fiber structures, then assembly speed increases, but cost and mechanism complexity increase
Solution Approach 1:
The patent extracts the complex expanding insert mechanism entirely and replaces it with a simpler recess-and-lug coupling system. The coupling device achieves secure fastening through geometric interlocking alone, eliminating the need for expanding elements, springs, or actuated mechanisms while maintaining rapid assembly capability.
Data Source
AI summary
A system and process for removably and replaceably coupling two hollow carbon fiber composite structures without the need for adhesives or welding. A universal coupling makes use of reciprocating catches in the end regions of the universal coupling. The reciprocating catches engage receiving features provided in the hollow carbon fiber composite structures to couple the hollow carbon fiber composite structures to the universal coupling, and through the universal coupling, couple the hollow carbon fiber composite structures together. The hollow carbon fiber composite structures can be uncoupled by disengaging the reciprocating catches of the universal coupling from the receiving features of the hollow carbon fiber composite structures.