Fiber Composite Seam Connection with Foldover Edge
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Solution Overview
Problem
The existing methods for connecting fiber composite materials in vehicle production, such as in aircraft, are complex and often require drilling holes for rivets or adhesive bonding, which can be inefficient and prone to delamination, especially in load-bearing regions.
Innovation Solution
A method and apparatus for connecting fiber composite sub-elements using a seam connection with a foldover at the edge of one sub-element, allowing for a simpler and more reliable connection by folding and intermeshing deformable edge regions, which can include metallic materials and thermoplastic matrices, reducing the need for drillholes and enhancing structural strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If rivets are introduced into drilled holes to connect fiber composite elements, then the sub-elements can be connected, but the manufacturing complexity increases and the structural integrity decreases due to drillholes
Solution Approach 1:
The invention extracts and eliminates the drillholes from the connection process. Instead of creating holes through the sub-elements for rivets, the method uses seam welding to join the edges of the sub-elements directly, removing the harmful drillholes and associated manufacturing complexity while maintaining structural integrity
Solution Approach 2:
The invention replaces the mechanical rivet system with a thermal-seam welding process. The seam weld creates a continuous bond along the edge regions without requiring drillholes or separate fastening elements, thereby simplifying the manufacturing process and improving structural reliability
2Productivity
If adhesive bonding is used to connect fiber composite sub-elements, then the connection can be achieved, but the manufacturing complexity and time increase
Solution Approach 1:
The invention replaces the adhesive bonding process with seam welding. This substitution eliminates the need for adhesive application, curing time, and associated fixtures, thereby reducing manufacturing complexity and increasing connection speed through a more direct thermal joining process
Solution Approach 2:
The seam welding process creates a continuous bond along the entire edge region in a single operation, whereas adhesive bonding requires application, positioning, and curing steps that are sequential and time-consuming. This continuous action significantly improves productivity
3Strength
If drillholes are created for rivet connection, then the sub-elements can be joined, but material waste increases and structural strength decreases
Solution Approach 1:
The invention extracts and eliminates the drillholes from the connection process. By joining edge regions through seam welding without creating holes, the method prevents material waste from removed sections and maintains the full structural strength of the fiber composite sub-elements
Solution Approach 2:
The seam weld merges the edge regions of the sub-elements into a continuous bonded structure. This merging creates a strong joint that preserves the integrity of the original materials without the need for drillholes that would compromise structural strength or create material waste
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 approach simplifies the connection process, reduces material waste, enhances structural integrity, and provides a hermetically sealed, high-strength bond with lower manufacturing complexity and pressure requirements compared to traditional methods, while minimizing delamination risks.
Implementation Method 1
a heating device (52) for heating (H) at least a sub-region to be formed of the edge region
Implementation Method 2
a bending device (60) for bending the edge region to give a foldover
Data Source
AI summary
Connections of sub-elements formed at least partly from fiber composite materials of a component for an aircraft with relatively low manufacturing complexity and the same or improved reliability and improved sealing, by providing different seam connections between the sub-elements. For this purpose, at least an edge region, formed from fiber composite material, of the first sub-element is formed to give a foldover that engages with an edge region of the other sub-element. Preferably, the forming is effected especially with use of thermoplastic materials while heating preferably the entire edge region.