Composite Assembly Element with Grooves for Structural Bonding
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Solution Overview
Problem
The production of complex composite structures for heavily loaded applications, such as in aeronautical constructions, is hindered by the need for assembly holes that increase mass and require local reinforcements, as well as the complexity and cost of industrial processes due to the use of traditional assembly methods.
Innovation Solution
An assembly method using composite material assembly elements with integral wings and grooves, subjected to partial thermal curing to achieve dimensional stability and thermoplastic properties, allowing for precise positioning and pressure application to form structural connections between elementary parts, thereby simplifying the assembly process and reducing mass penalties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional assembly methods with fasteners and assembly holes are used, then structural connection is achieved, but mass increases due to local reinforcements and holes
Solution Approach 1:
The assembly element merges the connection function and sealing function into a single integrated component. The groove receives the edge of the elementary part directly, eliminating the need for separate fasteners and sealants, thereby reducing mass while maintaining structural integrity
Solution Approach 2:
The invention extracts and eliminates the assembly hole from the elementary parts by using a groove-based system on the assembly element. This removes the need for local reinforcements around holes, reducing mass penalties while preserving connection strength
2Reliability
If traditional assembly methods with sealants are used, then sealing between parts is achieved, but production complexity and cost increase
Solution Approach 1:
The assembly element combines the sealing function with the structural connection function in a single component. The groove structure provides both mechanical connection and sealing, eliminating the need for separate sealant application steps and reducing production complexity
Solution Approach 2:
The groove structure of the assembly element provides self-sealing through its geometry. The groove receives and constrains the edge of the elementary part, creating an inherent seal without requiring additional sealant materials or application processes
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 method enables the assembly of complex composite structures with reduced mass and production complexity, ensuring precise connections and structural integrity while maintaining the lightweight and resistant properties of composite materials.
Implementation Method 1
b1) being made of composite material composed of fibers impregnated with a resin capable of hardening by polymerization during thermal cooking; b3) being subjected to partial thermal curing having the effect of partially polymerizing the resin of the assembly element
Implementation Method 2
b3) being subjected to partial thermal curing having the effect of partially polymerizing the resin of the assembly element on the one hand up to a stage where the element has acquired sufficient dimensional stability
Implementation Method 3
d) raising the temperature, at least locally, to a thermoplastic forming temperature of the wings and applying a pressure P to the wings to apply the wings to the faces of the elementary parts
Data Source
Figure 1~2
Figure 3~4a
Figure 5a~5e
AI summary
To produce a complex structure made of a composite, with assembled individual parts (1a, 1b), the method comprises the steps of: - producing the individual parts (1a, 1b); - producing assembly components (2), to ensure structural bonds between the individual parts (1a, 1b), from fibres impregnated with a resin capable of curing by polymerization, comprising fins (22a, 22b) attached to a core (21) that determine grooves (23a, 23b), in order to receive edges (11a, 11b) of the individual parts, subjected to a partial thermal cure to partially polymerize the resin and give the components a dimensional stability and thermoplastic properties; - positioning of the individual parts (1a, 1b) and assembly components (2); - raising the temperature to a thermoplastic forming temperature and applying a pressure P in order to apply the fins (22a, 22b) to faces (13a, 13b) of the individual parts (1a, 1b); - carrying out a complete thermal cure for polymerization of the resin of the assembly components (2).