Y-Shaped Composite Coupler for Lightweight Pressure Vessel Joints
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Solution Overview
Problem
Existing designs for joining multiple pressure vessels or fuselages, such as the double bubble fuselage, face challenges in creating a strong and lightweight three-way joint that can withstand loads without delamination of composite structures.
Innovation Solution
A composite attachment coupler with a Y-shaped configuration, utilizing warp tows in the longitudinal direction and cross-woven weft tows, which are wound around a central cluster of tows to enhance strength, is used to join adjacent tube structures and a central panel, thereby forming a robust multi-way joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional joining structures are used for multi-way joints in composite pressure vessels, then the structure can be manufactured with conventional methods, but the joint strength is insufficient and delamination occurs under load
Solution Approach 1:
The patent employs composite materials with specific fiber orientations (0°, ±45°, 90° plies) in the coupling structure to achieve superior mechanical properties. The composite laminate configuration provides enhanced strength and delamination resistance compared to conventional homogeneous materials, directly resolving the contradiction between joint strength and delamination resistance.
Solution Approach 2:
The coupling structure features localized reinforcement at the multi-way joint area with extended tows that protrude from the composite surface. This local quality enhancement concentrates strength where it is most needed (at the joint) without requiring overall structural reinforcement, thereby improving joint strength and delamination resistance precisely where required.
2Strength
If heavier joining structures are used to increase joint strength, then the joint can withstand higher loads, but the overall weight of the pressure vessel increases
Solution Approach 1:
The use of high-strength composite materials allows the joint to achieve superior load-bearing capacity with significantly reduced mass compared to traditional metallic joining structures. The composite coupling weighs less while providing equal or superior strength, directly resolving the contradiction between joint strength and overall weight.
Solution Approach 2:
The coupling structure is segmented into distinct functional zones: core tows for primary load bearing, extended tows for stress distribution, and surface plies for environmental protection. This segmentation allows each component to be optimized for its specific function, achieving high joint strength with minimal weight by eliminating unnecessary material.
3Reliability
If the coupling structure uses extensive fiber reinforcement to prevent delamination, then delamination resistance improves, but the manufacturing complexity increases
Solution Approach 1:
The extended tows are incorporated into the composite laminate structure during the manufacturing process before final curing. This preliminary action ensures that the stress-distributing extended tows are properly embedded and bonded to the substrate, achieving delamination resistance without requiring complex post-manufacturing assembly operations.
Solution Approach 2:
The coupling structure nests multiple functional elements within a unified composite laminate: core tows are embedded within the laminate thickness, extended tows protrude from the surface, and surface plies envelope the entire structure. This nested configuration achieves comprehensive delamination protection while maintaining a relatively simple monolithic manufacturing process.
Data Source
AI summary
A joining structure adapted to join adjacent tube structures together while providing high strength with low weight. The joining structure may be of composite materials, and may include warp tows in the longitudinal direction of the tubes and have weft tows cross-woven into a fabric, which may be a carbon fiber. The joining structure may be Y-shaped and adapted to join three composite sheets together. The weft tows may also be wound around a central cluster of tows, or tows, which may provide extra strength. The tubes may be pressurized in use, such as in an aircraft fuselage.