Composite Fastening via Distance Compensation Insert
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Solution Overview
Problem
Existing devices for connecting structural elements made of fiber-reinforced plastic composite materials face issues such as damage from tightening torque, space constraints, and unsightly protruding screw heads, making them unsuitable for applications like aircraft construction where stability and aesthetics are critical.
Innovation Solution
A device that integrates a distance compensation element via a threaded connection to an insert part, which is glued within the structural element, allowing for adhesive bonding and avoiding external load introduction, thus providing a space-saving and aesthetically pleasing solution by converting the rotational movement of the connecting screw into axial extension within the structural element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the screw head is supported on the component to maintain stability, then the connecting strength is improved, but the component may be damaged by tightening torque and the appearance is degraded
Solution Approach 1:
The screw head is extracted from the component surface and relocated to the distance compensation element. The distance compensation element acts as an intermediary carrier that bears the tightening torque and connecting strength requirements, while the component surface remains undisturbed and undamaged.
Solution Approach 2:
The distance compensation element serves as an intermediary between the screw head and the component. It absorbs the mechanical stress and torque during tightening, preventing direct contact and potential damage to the component while maintaining the necessary connecting strength.
2Adaptability or versatility
If the distance compensation element is connected to the nut of the retaining element, then the tolerance compensation function is achieved, but space problems occur making it unsuitable for composite components
Solution Approach 1:
The distance compensation element is merged with the insert part by integrating the threaded connection directly into the insert part structure. This consolidation eliminates the need for separate nuts and retaining elements, significantly reducing the overall space requirements while maintaining the tolerance compensation function.
Solution Approach 2:
The threaded connection of the distance compensation element is nested within or integrated into the insert part structure. This nesting approach allows the distance compensation mechanism to occupy minimal additional space within the existing component geometry, making it suitable for thin-walled composite components.
3Device complexity
If the connecting screw is fixed with the screw head on the upper side of the composite material, then the connection is simplified, but the structural integrity is compromised due to punctiform load introduction
Solution Approach 1:
The screw head is extracted from direct contact with the composite material surface. The distance compensation element with its threaded connection serves as an intermediate structure that distributes loads away from the composite material, preventing punctiform stress concentration and preserving structural integrity.
Solution Approach 2:
The distance compensation element acts as a mediator between the connecting screw and the composite structural element. It provides a transition that distributes mechanical loads over a larger area, avoiding concentrated stress points that would compromise the composite material's structural integrity.
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 design enhances the structural integrity and safety of composite materials while maintaining a clean surface appearance, offering a resilient and stable connection suitable for thin-walled fiber-reinforced plastic components, particularly in aircraft construction.
Implementation Method 1
fixed immovably to the adjacent material of the structural element by means of an adhesive connection
Implementation Method 2
Frictional engagement with the connecting screw connectable entraining element, so that the distance compensation element can be converted into a stop position
Data Source
Figure 1~2
Figure 3~7
Figure 4a~4b
AI summary
Device (4) for spaced apart connection of a structural element (1), in particular made from a fiber-reinforced plastic composite material, with a holding element (5) by means of a connection screw (7), with a distance compensation element (8) having a longitudinal bore (9) for the passage of the connection screw (7), and with an entraining element (16) arranged in the longitudinal bore (9), which can be connected to the connection screw (7) by means of a friction fit, so that the distance compensation element (8) can be transferred into an abutment position bridging the distance between the structural element (1) and the holding element (5) by screwing in of the connection screw (7), wherein the distance compensation element (8) is connected to an insertion part (11) via a screw connection (10), which part comprises a fastening section (12) that can be arranged within the structural element (1) for bonding with the structural element (1).