Co-molded Washer Connector Assembly for Lightweight Structural Joints
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Solution Overview
Problem
In applications where weight is a critical consideration, such as the aircraft industry, existing connector fittings made of composite materials face challenges in securely attaching to orthogonal surfaces without requiring additional hardware, leading to inefficiencies in assembly and potential structural weaknesses.
Innovation Solution
A connector assembly comprising a fitting formed of composite material with long strand fibers and resin, featuring angled mounting portions, a joint portion, and integrated washers or inserts, which allows for secure attachment to members with minimal additional hardware, utilizing molecular chain bonding or curing to form an integral assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite material fittings are used to reduce weight, then weight efficiency is improved, but structural integrity and secure attachment capability deteriorate
Solution Approach 1:
The fitting is formed of composite material including generally long strand fibers and resin, providing weight reduction while maintaining structural integrity through the fiber-reinforced composite structure
Solution Approach 2:
The washer is joined to the second mounting portion to form an integral assembly, combining multiple components into a unified structure that eliminates the need for separate hardware while maintaining attachment capability
2Strength
If special washers and additional hardware are used to ensure secure attachment, then structural integrity is improved, but device complexity and assembly time increase
Solution Approach 1:
The washer is integrally joined to the mounting portion of the fitting, merging what would traditionally be separate components into a single integrated assembly, thereby reducing the number of parts and simplifying the overall device
Solution Approach 2:
The integrated washer-m mounting portion assembly serves multiple functions simultaneously: it provides structural support, enables secure attachment to the second member, and eliminates the need for separate washers or additional hardware components
3Adaptability or versatility
If multiple separate components are used for mounting, then adaptability is improved, but ease of manufacture and assembly deteriorate
Solution Approach 1:
The washer and mounting portion are joined to form an integral assembly, reducing the number of discrete components that need to be manufactured and assembled, thereby simplifying the manufacturing process and assembly operations
Solution Approach 2:
The integrated assembly maintains adaptability by providing a universal mounting solution that can connect to various members while reducing assembly complexity through its pre-integrated structure
Data Source
AI summary
The connector assembly includes a fitting with a first mounting portion having two opposing surfaces and mounting hole(s) extending between the two surfaces for connecting with a first member. A second mounting portion extends angled with respect to the first mounting portion and has two opposing surfaces and mounting hole(s) extending between the two for connecting with a second member. A joint portion integrally connects the first and second mounting portions. One or more washers each have opposing upper and lower surfaces and at least one hole extending between the two surfaces, each receiving a fastener for attaching the second mounting portion to the second member. The washer lower surface is disposed on the second mounting portion inner surface such that the washer opening is centered about the at least one mounting hole axis. Each washer is joined to the second mounting portion to form an integral assembly.