Composite Live Hinge for Structural Composites
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Solution Overview
Problem
Conventional live hinges formed from a single piece of material are inadequate for structural composites, as they require material weakening, leading to limited flexibility and fatigue life, especially when used in stiff materials like those found in aircraft components.
Innovation Solution
A composite live hinge is developed using multiple layers of materials, including a tensile fabric and elastomer, allowing for customization of strength and flexibility without the need for material weakening, and enabling nearly unlimited fatigue life with a full 360° angular range of movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional live hinges are formed from a single piece of material, then the hinge can be simple in structure, but the material must be weakened which limits flexibility and fatigue life
Solution Approach 1:
The patent applies composite materials by combining an elastomer layer with a tensile fabric layer to create a live hinge that achieves both high flexibility and extended fatigue life without requiring material weakening. The elastomer provides elastic deformation capability while the tensile fabric reinforces the structure, allowing the hinge to withstand repeated cycling without the limitations of monolithic materials.
Solution Approach 2:
The patent segments the hinge into distinct functional layers: an elastomer layer for flexibility and a tensile fabric layer for strength. This segmentation allows each layer to perform its specific function optimally, with the elastomer handling deformation and the fabric providing structural reinforcement, thereby achieving high reliability without compromising flexibility.
2Strength
If material weakening is applied to create a hinge joint, then the hinge can be formed in stiff materials, but the flexibility and fatigue life are limited
Solution Approach 1:
The composite construction using elastomer and tensile fabric allows the hinge to maintain full strength of the parent structure while achieving the necessary flexibility for hinged movement. The tensile fabric carries the structural loads while the elastomer provides the bending capability, eliminating the need to compromise material strength through weakening.
3Stability of the object's composition
If conventional live hinges are used in structural composites, then the hinge can be integrated into the structure, but the stiffness of the material prevents adequate flexibility
Solution Approach 1:
The patent uses a composite material system where the elastomer layer provides the necessary flexibility for hinged movement while the tensile fabric layer maintains structural integrity. This composite approach allows the hinge to be integrated into structural composite applications without compromising either flexibility or structural stability.
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
The composite live hinge provides enhanced strength, flexibility, and extended fatigue life without the need for material weakening, making it suitable for applications in structural composites, such as aircraft components, with design redundancy ensuring continued functionality even after elastomer failure.
Implementation Method 1
The composite live hinge includes an elastomer layer that provides flexibility and elastic deformation to enable hinged movement between components
Implementation Method 2
The composite live hinge includes a tensile fabric layer that resists tensile forces and maintains structural integrity during hinge movement
Data Source
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AI summary
A hinged component includes first and second portions of material coupled together by a composite live hinge. The live hinge includes a layer of tensile fabric and a layer of elastomer interposed between the tensile fabric and the material of one or both of the coupled first and second portions. The composite live hinge is capable of joining structural composite materials without the need for scoring, and thereby weakening, the structural composite material along the desired hinge line. The live hinge can be embedded in the materials it joins in a method that is compatible with traditional structural composite layup processes and in a manner which prevents resin from the structural composite materials from infiltrating the tensile fabric and compromising its flexibility.