Composite Lug Ply Architecture for Buckling-Resistant Load Transfer

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Solution Overview

Problem

Existing composite materials face challenges in efficiently transferring loads in aerospace applications due to the limitations of metallic joints, which increase weight and cost, and fully composite designs with weak structural performance and high manufacturing costs.

Innovation Solution

A composite part design featuring finite-length composite plies with specific fiber orientations and polymer matrices, wrapped in a clockwise and counter-clockwise direction, providing additional transverse compression and minimizing the risk of local buckling, with optional interleaving and additional composite wrapping for enhanced structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If metallic joints are used at rod ends for load transfer, then load transfer efficiency is improved, but overall weight increases and cost increases

Engineering Contradiction:

Improveload transfer efficiencyVSAvoidoverall weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates the metallic joint component from the composite structure, replacing it with a fully composite design where the composite material itself forms the load-bearing ending part, thereby removing the source of additional weight while maintaining load transfer capability through optimized composite ply architecture

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs advanced composite material techniques, specifically using multiple layers of composite plies with different fiber orientations (including circumferential, longitudinal, and helical orientations) to create a fully composite ending part that achieves both lightweight construction and efficient load transfer, replacing traditional metallic joints

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If fully composite designs with composite ending parts are used, then weight is reduced, but structural performance becomes weak

Engineering Contradiction:

Improveoverall weightVSAvoidstructural performance

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies local quality by varying the fiber orientation and ply configuration in different regions of the composite ending part - using circumferential plies near the load application point for hoop strength, longitudinal plies for axial load carrying, and helical plies for shear resistance, thereby optimizing structural performance locally throughout the component

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent introduces three-dimensional fiber orientations including helical and circumferential plies in addition to traditional longitudinal plies, creating a multi-directional load path architecture that significantly enhances structural performance in all critical directions while maintaining the lightweight composite construction

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Strength

If complex fabrication methods like braiding techniques are used for fully composite components, then structural performance is improved, but manufacturing cost increases

Engineering Contradiction:

Improvestructural performanceVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent segments the composite ending part into distinct ply layers with specific fiber orientations (circumferential, longitudinal, helical plies) that can be manufactured using standard composite fabrication processes, avoiding the need for complex braiding techniques while achieving superior structural performance through the segmented, multi-directional ply architecture

Inventive Principle:

Principle #1Segmentation

4Manufacturing precision

If post-fabrication machining is performed on composite components, then dimensional precision is improved, but risk of polymer damage increases

Engineering Contradiction:

Improvedimensional precisionVSAvoidrisk of polymer damage

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The patent performs preliminary action by designing the composite ending part with built-in dimensional features and precise geometries during the fabrication process itself, using controlled ply layup and curing to achieve final dimensions, thereby eliminating or minimizing the need for subsequent machining operations that could damage the polymer matrix

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20230204071A1Composite lug with enhanced performance

Publication Date: 2023.06.29 HAMILTON SUNDSTRAND CORP

AI summary

A composite part is provided and includes a component, a first set of first composite plies with finite lengths and a second set of second composite plies with finite lengths. A respective end of each of the first composite plies is wrapped around the component in a clockwise wrapping direction and includes first fibers. A respective end of each of the second composite plies is wrapped around the component in a counter-clockwise wrapping direction and includes second fibers.