Angled Composite Fitting Boss Structure for Lightweight Load Transfer
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Solution Overview
Problem
Existing connector assemblies for angularly arranged members in weight-sensitive applications, such as the aircraft industry, face challenges in efficiently transferring loads and providing structural reinforcement while maintaining a lightweight composite material design.
Innovation Solution
A composite material fitting with a first and second mounting portion, where the second mounting portion is angled and includes at least one elongated boss projecting outwardly to be disposed within a recess of the second member or stiffener, enhancing load transfer and structural reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If reinforcing members or stiffeners are used to connect the fitting with members, then structural reinforcement and load transfer are improved, but device complexity and weight increase
Solution Approach 1:
The boss structure integrates the reinforcing function directly into the fitting body by forming protrusions that extend into recesses of the members. This merging of the fitting and reinforcing elements into a single integrated component eliminates the need for separate stiffeners, thereby reducing device complexity while maintaining structural reinforcement capabilities.
Solution Approach 2:
The fitting is constructed from composite materials that provide high strength-to-weight ratio, enabling structural reinforcement without proportionally increasing weight. The composite structure allows the boss features to be formed integrally with the fitting body, combining reinforcement functionality with the main component.
2Strength
If reinforcing members or stiffeners are used to connect the fitting with members, then load transfer is improved, but weight increases
Solution Approach 1:
By integrating the boss reinforcing features directly into the fitting body as integral components, the design eliminates the need for additional separate stiffeners. This reduction in component count directly reduces overall assembly weight while maintaining the load transfer function through the integrated boss structures that extend into the members.
Solution Approach 2:
The use of composite materials for the fitting provides high strength and stiffness with lower density compared to traditional metals. This allows the integrated boss structures to achieve effective load transfer while the overall weight remains reduced due to the inherent weight advantages of composite materials.
3Strength
If the boss is disposed within a recess of the second member or stiffener, then load transfer and structural reinforcement are improved, but manufacturing precision requirements increase
Solution Approach 1:
The recesses in the members are pre-formed during member manufacturing to accommodate the boss protrusions. This preliminary preparation of receiving features allows for controlled tolerance accumulation, where the precision requirements are distributed across multiple manufacturing steps rather than requiring single-step high-precision fitting, thereby reducing overall manufacturing precision challenges.
Solution Approach 2:
The boss structure incorporates spacing distances and dimensional parameters that are optimized to provide adequate clearance and load transfer capability while accommodating normal manufacturing variations. By designing the boss-recess interface with appropriate dimensional tolerances and clearance parameters, the system achieves reliable load transfer without requiring extreme manufacturing precision.
Data Source
AI summary
A fitting includes a first mounting portion connectable with a first member and having opposing planar surfaces and inner and outer ends. A second mounting portion is angled with respect to the first mounting portion, is connectable with a second member and has opposing planar surfaces, an outer end and an inner end integrally formed with the first mounting portion inner end. A boss projects outwardly from the second mounting portion first surface and is disposable within a recess of the second member or a stiffener coupled with the second member. The boss has an inner end adjacent to the second mounting portion inner end, an outer end spaced from the inner end, a centerline between the boss inner and outer ends, and an outermost surface spaced from the second mounting portion first surface by a spacing distance having a value greater than zero at all points along the centerline.