Composite Laminate Joint with Prefailure Load-Introduction Indication
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Solution Overview
Problem
Conventional composite laminates for load-introduction joints in aerospace applications are complex, time-consuming, and expensive to manufacture, with limited design space and potential safety risks due to abrupt failure modes, especially when multiple bolts are used in close proximity.
Innovation Solution
A composite laminate with a prefailure indication element, such as cut-outs or recesses, that compresses or destructs under load, allowing for early detection of impending failures and reducing the contact surface area between the bolt and laminate, enabling safer and more efficient manufacturing with automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional composite laminates are used for load-introduction joints, then the joint can be manufactured, but the manufacturing process is complex, time-consuming, and expensive
Solution Approach 1:
The patent incorporates a prefailure indication element (such as a protrusion or recess) into the composite laminate structure before the actual load-introduction joint is assembled. This element is pre-positioned to interact with the load-introduction component, enabling automated manufacturing processes to detect and respond to potential failure conditions without requiring complex post-manufacturing inspection or adjustment procedures
Solution Approach 2:
The prefailure indication element acts as an intermediary between the composite laminate and the load-introduction component. It provides a detectable signal that mediates the interaction between these two components, allowing automated manufacturing systems to identify and correct potential issues during the assembly process itself, thereby simplifying overall manufacturing while maintaining safety
2Reliability
If conventional composite laminates without prefailure indication are used, then manufacturing is simpler, but safety risks increase due to abrupt failure modes
Solution Approach 1:
The patent applies the prefailure indication element only at specific critical locations within the composite laminate where load introduction occurs, rather than throughout the entire laminate structure. This localized approach provides the necessary safety indication functionality while minimizing the added structural complexity and maintaining manufacturing feasibility
3Strength
If multiple bolts are used in close proximity for load introduction, then load distribution is improved, but stress concentrations increase and manufacturing becomes more difficult
Solution Approach 1:
The prefailure indication elements are integrated directly into the composite laminate structure itself, eliminating the need for separate detection devices or complex manufacturing procedures. The laminate structure serves its own inspection function through these built-in indicators, allowing automated processes to easily identify and accommodate multiple closely-spaced load-introduction points without increasing manufacturing difficulty
Data Source
AI summary
A composite laminate for connection to at least one attachment component in a load-introduction joint, said composite laminate comprising an opening that is adapted to receive a load-introduction component of said load-introduction joint, wherein a prefailure indication element is provided in the region of said opening, said prefailure indication element being modifiable by said load-introduction component in a prefailure mode of said load-introduction joint for indication of an impending function-affecting failure of said composite laminate. The invention is further related to a corresponding load-introduction component.