Composite Connecting Rod Manufacturing with Open Profile Preform
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Solution Overview
Problem
Existing methods for manufacturing composite connecting rods are complex and limited in the variety of profiles they can produce, particularly requiring assembly of closed sections for mechanical resistance, which complicates the manufacturing process and restricts design flexibility.
Innovation Solution
A method involving a fibrous preform with interconnected primary plies, shaped to have an open section by keeping opposite edges apart, followed by resin injection and polymerization, eliminating the need for edge assembly and allowing for the production of connecting rods with open profiles such as C-shaped, U-shaped, or V-shaped designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If closed section profiles are used to ensure mechanical resistance, then strength is improved, but device complexity increases due to assembly requirements
Solution Approach 1:
The preform is divided into primary plies that are interconnected by links, allowing each ply to be shaped independently while maintaining structural integrity. This segmentation enables the creation of complex open profiles without requiring assembly of multiple closed sections.
Solution Approach 2:
Instead of assembling closed sections to achieve mechanical resistance, the invention inverts the approach by using open profiles with interconnected plies that derive strength from the ply interconnections and resin impregnation, eliminating the need for complex assembly operations.
2Strength
If edge assembly steps are added to create closed sections, then strength is improved, but manufacturing precision requirements increase
Solution Approach 1:
The preform is pre-shaped with interconnected primary plies before resin impregnation, establishing the structural framework in advance. This preliminary action eliminates the need for subsequent edge assembly operations and their associated precision requirements.
Solution Approach 2:
Resin acts as an intermediary that binds the interconnected primary plies together, transferring loads and providing structural integrity without requiring precise mechanical assembly of edges. The resin impregnation process is more tolerant of positioning variations than mechanical joining.
3Ease of manufacture
If open profiles are used to simplify manufacturing, then ease of manufacture is improved, but strength may be compromised
Solution Approach 1:
The invention uses composite construction with multiple primary plies interconnected by links and impregnated with resin, creating an open profile that maintains high compressive strength through the composite structure rather than relying on closed section geometry.
Solution Approach 2:
The interconnected primary plies provide localized reinforcement at critical areas of the open profile, allowing the structure to achieve necessary strength characteristics in specific regions while maintaining overall manufacturing simplicity.
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
This approach simplifies the manufacturing process, enables the production of a wide range of open-profile connecting rods with significant mechanical strength, suitable for applications like landing gear, while accommodating deformation and providing necessary compressive strength through strategic reinforcement.
Implementation Method 1
injection of resin and cause its polymerization
Data Source
Figure 1~3
Figure 4~5
AI summary
The present invention relates to a method for manufacturing a composite material connecting rod using a fibrous preform (2) comprising a number of primary folds of fibres connected together by links enabling the folds to slide over one another when shaping the preform, the preform comprising a central portion (8) for forming the body of the connecting rod and comprising two opposite side edges (6, 7), and extensions (9) for forming yokes of the connecting rod, said method comprising the step of shaping the fibrous preform in order to provide same with a hollow shape while keeping the opposite side edges separated in order to provide the fibrous preform with an open profile at the central portion, and then proceeding to inject resin and to polymerise said resin.