Integrated Mounting Lug Structure for Composite Laminate Load Transfer
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Solution Overview
Problem
Existing methods for load introduction in fiber composite laminate parts for aircrafts are inefficient and require multiple components, leading to complex assembly and increased weight.
Innovation Solution
A method involving the integration of a longitudinal fiber structure to form an integral load introduction feature by pulling it through a laminate structure, forming an opening, and curing it with the laminate to create a single unitary member, reducing the need for external brackets and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal bracket inserts and external brackets are used for load introduction, then the load carrying capacity is sufficient, but the device complexity and assembly complexity increase
Solution Approach 1:
The patent merges the load introduction feature directly into the fiber composite laminate part by integrating longitudinal fiber structures (cords) that extend through the laminate thickness. This eliminates the need for separate metal bracket inserts and external brackets, combining multiple components into a single integrated structure that maintains load carrying capacity while reducing assembly complexity
Solution Approach 2:
The patent uses composite material structures by incorporating longitudinal fiber cords (such as carbon fiber or glass fiber) within the fiber composite laminate. These cords are embedded in the matrix material and oriented to carry loads in the thickness direction, creating a composite reinforcement system that provides structural strength without requiring separate metal fastening components
2Strength
If metal bracket inserts and external brackets are used for load introduction, then the load carrying capacity is sufficient, but the weight increases
Solution Approach 1:
The patent replaces heavy metal bracket inserts and external brackets with lightweight fiber composite cords embedded in the laminate. The longitudinal fiber structures (typically carbon fiber or glass fiber cords) provide the necessary load carrying capacity while being significantly lighter than metal alternatives, thus reducing the overall part weight while maintaining structural strength
Solution Approach 2:
By integrating the load introduction feature directly into the laminate structure through embedded fiber cords, the patent eliminates the need for separate metal fastening components. This integration removes the additional weight that would be required for metal brackets, inserts, and associated fasteners, achieving weight reduction while maintaining load carrying capacity
3Strength
If multiple components are used for load introduction, then the load carrying capacity is sufficient, but the number of parts increases
Solution Approach 1:
The patent combines multiple separate components (metal bracket inserts, external brackets, fasteners) into a single integrated fiber composite laminate structure. The longitudinal fiber cords are embedded within the laminate during manufacturing, creating an integrated load introduction feature that eliminates the need for multiple separate parts and reduces the total number of components required
Data Source
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AI summary
In order to improve load introduction into a fiber composite laminate part (52), the invention proposes to integrate a mounting lug (54) by pulling a cord (18) through an initial laminate structure (10) such that an opening (30) is formed. The ends (20, 22) of the cord (18) are split and pressed onto the laminate structure (10) thereby forming fixing members (36) that are subsequently covered by another laminate structure (38). Laminate patches (42) may be arranged next to the fixing members (36) so as to improve smoothness of the surface. The mounting lug (54) may be clamped between two plates (58) for mounting to another structure.