Composite Corner Element for Non-Coplanar Structural Connections
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Solution Overview
Problem
Existing composite structural elements for air vehicle structures often rely on metallic connectors, which can lead to corrosion issues and increased costs, and struggle to efficiently connect non-metallic load-bearing members in load-bearing applications.
Innovation Solution
A composite structural member comprising flange and web elements made from different composite materials, connected via corner elements with specific fiber orientations and radii, allowing for non-coplanar connections that provide C-shaped or L-shaped transverse cross-sections, enabling efficient load transfer without metallic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic pins are used to connect non-metallic load bearing members, then shear loads and bending loads can be transmitted between members, but corrosion issues occur and costs increase
Solution Approach 1:
A composite material connector serves as an intermediary element between non-metallic load bearing members, replacing metallic pins. The connector is composed of multiple fiber layers with different orientations (0°, 90°, ±45°) that work together to transmit shear and bending loads while being corrosion-resistant like the surrounding composite structure.
Solution Approach 2:
The connector is constructed from composite materials consisting of multiple layers of fibers (carbon, glass, or aramid) embedded in a polymer matrix. Different fiber orientations in different layers provide anisotropic mechanical properties optimized for load transmission in multiple directions, while the composite structure itself resists corrosion.
2Strength
If metallic connectors are used in air vehicle structures, then load bearing connections can be achieved, but capital costs increase
Solution Approach 1:
The connector is made from the same composite material system as the surrounding air vehicle structure, ensuring material homogeneity. This allows all components to be manufactured using the same composite fabrication processes (autoclave curing, resin transfer molding, or automated tape laying), eliminating the need for separate metallic connector manufacturing and assembly operations.
Solution Approach 2:
The connector integrates multiple functional layers (different fiber orientations) into a single composite component that performs both structural and connection functions. This merging of functions into one homogeneous material system simplifies the supply chain and manufacturing process compared to using separate metallic connectors.
3Shape
If composite structural elements are designed with non-coplanar connections, then C-shaped or L-shaped cross-sections can be formed, but manufacturing complexity increases
Solution Approach 1:
The connector is segmented into multiple layers, each with specific fiber orientations (0°, 90°, ±45°) that correspond to different stress directions. This segmentation allows each layer to be optimized for specific load paths while collectively forming the complex non-coplanar C-shaped or L-shaped cross-section required for the air vehicle structure.
Solution Approach 2:
Different regions of the connector have different fiber orientations tailored to local stress requirements. The 0° layers handle axial loads, 90° layers handle transverse loads, and ±45° layers handle shear loads. This local optimization of material properties enables the formation of complex non-coplanar geometries while maintaining structural efficiency.
Data Source
AI summary
A composite structural member including at least one first flange element made from a first composite material, and at least one first web element made from a second composite material. The at least one first web element is connected to at least one first flange element in a non-coplanar manner along a corresponding mutual first edge via a first corner element made from a third composite material, the mutual first edge extending along a first direction. The third composite material includes a corresponding first plurality of third composite material first fibers and a corresponding second plurality of third composite material second fibers embedded in a corresponding third composite material matrix in a non-parallel orientation with respect to the third composite material first fibers, wherein the third composite material first fibers are nominally orthogonal to the mutual first edge or to the first direction.