Composite Load Introduction Structure to Prevent Layer Unfolding
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Solution Overview
Problem
The design of fiber-reinforced aerodynamic structures faces challenges in load transmission, particularly the 'unfolding' of layers, while requiring low manufacturing/assembly costs and stable processes.
Innovation Solution
A load introduction system with a longitudinal connection element anchored at the upper skin section and extending through the lower skin section, coupled with a sleeve element to clamp the attachment unit against the lower skin section, ensuring tension forces are primarily applied, reducing shear and compression forces on radii between spar elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional load transmission methods are used in fiber-reinforced structures, then assembly is simplified, but layer unfolding occurs reducing structural stability
Solution Approach 1:
The connection element is divided into multiple segments including a first connection portion anchored to the upper skin section, a second connection portion anchored to the attachment unit, and an intermediate portion extending through the lower skin section. This segmentation allows the load to be distributed along the fiber-reinforced structure without concentrating stress at single points that would cause layer unfolding.
Solution Approach 2:
The connection element is specifically designed to engage with fiber-reinforced material layers at critical locations (upper and lower skin sections) while maintaining a streamlined profile through the intermediate portion. This local quality enhancement ensures that load transmission occurs through the fiber layers without disrupting their structural integrity, preventing layer unfolding while maintaining assembly simplicity.
2Device complexity
If fiber-reinforced materials are used to reduce part number, then manufacturing complexity increases due to material behavior differences
Solution Approach 1:
The connection element is designed with pre-determined anchoring features at the upper and lower skin sections that are specifically configured for fiber-reinforced materials. The intermediate portion is shaped to pass through the lower skin section without disrupting fiber alignment. This preliminary design consideration simplifies the manufacturing process by accounting for fiber-reinforced material behavior upfront, reducing the need for complex post-manufacturing adjustments.
Solution Approach 2:
The intermediate portion of the connection element acts as an intermediary that bridges the upper and lower skin sections while passing through the fiber-reinforced lower skin section. Its streamlined design allows it to navigate through the composite material without causing delamination or fiber disruption, thereby simplifying the integration of fiber-reinforced components into the overall structure.
3Strength
If longitudinal connection element extends through lower skin section, then load transmission is improved, but aerodynamic interference increases
Solution Approach 1:
The connection element transitions from a potentially protruding configuration to a streamlined profile that conforms to the aerodynamic surface. By routing the intermediate portion through the lower skin section and shaping it to follow the contour of the aerodynamic structure, the design maintains load transmission functionality while minimizing disruption to airflow in the critical aerodynamic dimension.
Solution Approach 2:
The intermediate portion of the connection element is designed with a streamlined, film-like profile that conforms to the aerodynamic surface contour. This thin, aerodynamically shaped configuration allows the connection element to transmit loads effectively while presenting minimal aerodynamic interference, as the streamlined form allows airflow to pass smoothly over the structure.
Data Source
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AI summary
The invention relates to a load introduction system (1), comprising an aerodynamic structure component (10) having an upper skin section (11) and a lower skin section (12), an attachment unit and a load introduction unit (30) configured to couple the attachment unit (20) to the aerodynamic structure component (10). The load introduction unit (30) comprises a longitudinal connection element (31) with its first end (31a) positioned at the upper skin section (11). The longitudinal connection element (31) extends through the lower skin section (12) such that its second end (31b) is positioned outside of the aerodynamic structure component (10). The first end (31a) is anchored to the upper skin section (11) and the second end (31b) is anchored to the attachment unit (20) such that the longitudinal connection element (31) forces the attachment unit (20) against the lower skin section (12).