Composite Core Attachment Rail for Non-Parallel Support Structures

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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 the use of angled or L-shaped configurations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If fillers and additives are used to adhere composite core material to surrounding structure, then attachment capability is improved, but weight increases and structural stability is compromised

Engineering Contradiction:

Improveattachment capabilityVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates the filler material from the attachment system, replacing it with a mechanical attachment rail that interfaces directly with the composite core structure through routed channels, thereby removing the source of weight increase while maintaining attachment capability

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The attachment rail serves as an intermediary component between the composite core structure and surrounding support members, providing a dedicated mechanical interface that eliminates the need for fillers and additives while enabling secure attachment

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If fillers and additives are used to adhere composite core material to surrounding structure, then attachment capability is improved, but structural stability deteriorates

Engineering Contradiction:

Improveattachment capabilityVSAvoidstructural stability

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent removes filler materials that compromise structural stability and replaces them with a clean mechanical attachment system using rails and channels that maintain the integrity of the composite core structure without introducing destabilizing substances

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The attachment rail is constructed as a composite structure with a channel system that integrates with the composite core, providing both attachment functionality and structural stability through the composite material properties

Inventive Principle:

Principle #40Composite materials

3Strength

If fillers and additives are used to adhere composite core material to surrounding structure, then attachment capability is improved, but harmful factors increase

Engineering Contradiction:

Improveattachment capabilityVSAvoidwaste and harmful chemicals

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent extracts and eliminates filler materials and additives from the attachment process, replacing them with a mechanical attachment rail system that requires no chemical substances, thereby eliminating waste generation and harmful chemical emissions

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The attachment rail system uses durable, reusable mechanical components instead of consumable filler materials, eliminating the need for ongoing material consumption and waste generation associated with filler-based attachment methods

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

4Strength

If connection features are used to attach composite core material, then attachment capability is improved, but adaptability deteriorates

Engineering Contradiction:

Improveattachment capabilityVSAvoidoptions for passage of lines and hoses

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The attachment rail incorporates a multi-functional channel system that simultaneously provides attachment capability and serves as a passage way for lines, hoses, air lines, and fuel lines, thereby eliminating the trade-off between attachment and adaptability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent adds a third dimension to the attachment rail by incorporating routed channels that extend through the rail structure, creating a pathway dimension that allows lines and hoses to pass through without compromising the attachment function

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS11891172B2Devices and methods to attach a composite core to a surrounding structure

Publication Date: 2024.02.06 SIERRA NEVADA CORP

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.