Composite Lug Ply Wrapping for Lightweight Load Transfer
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Solution Overview
Problem
Existing composite materials face challenges in efficiently transferring loads in aerospace applications due to structural weaknesses and increased costs associated with metallic joints, and fully composite designs with non-metallic ending parts often require complex fabrication methods and post-fabrication machining, which can lead to polymer damage and design limitations.
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 around a component, providing additional transverse compression and minimizing risks of local buckling through interleaved and transversely oriented plies, forming an angular or rounded neck at a distance from the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic joints are used at rod ends to transfer loads, then load transfer efficiency is improved, but overall weight increases and cost increases
Solution Approach 1:
The patent removes metallic joints from the composite structure by extending the composite material itself to form lug endings. The composite plies are wrapped around the rod ends to create integrated composite lugs that eliminate the need for separate metallic joint components, thereby reducing weight while maintaining load transfer capability.
Solution Approach 2:
The patent uses composite materials with specific fiber orientations and stacking sequences to create lug endings that can efficiently transfer loads. The composite plies are arranged with fibers oriented to handle tensile and compressive loads, replacing metallic joints with composite structures that maintain strength while reducing weight.
2Weight of moving object
If fully composite designs with non-metallic ending parts are used, then weight is reduced, but structural performance deteriorates due to polymer matrix being the driving reason for failures
Solution Approach 1:
The patent applies different ply orientations and material properties at different locations within the composite lug. The fiber orientations are specifically tailored for each region to handle local stress states, with plies oriented to resist tensile loads in one direction and compressive loads in another, optimizing structural performance throughout the component.
Solution Approach 2:
The patent transitions from unidirectional fiber reinforcement to multi-directional fiber reinforcement by wrapping composite plies around the rod ends in various orientations. This creates a three-dimensional fiber architecture that distributes loads more effectively through the polymer matrix, preventing matrix-dominated failure modes.
3Adaptability or versatility
If complex fabrication methods such as braiding techniques are used to create fully composite components, then metallic joints are eliminated, but manufacturing cost increases and design limitations increase
Solution Approach 1:
The patent divides the composite component into distinct sections: a main body and separate lug endings. The lug endings are formed by wrapping composite plies around the rod ends, which can be done as a separate manufacturing step. This segmentation allows the use of simpler, more cost-effective fabrication methods compared to complex braiding techniques while still achieving fully composite construction.
Solution Approach 2:
The patent incorporates the lug endings into the composite manufacturing process by pre-positioning the rod ends and wrapping plies around them during layup. This preliminary action integrates the lug formation into the main manufacturing process, eliminating the need for separate complex braiding operations and reducing overall manufacturing cost and time.
4Manufacturing precision
If post-fabrication machining is performed on composite components, then precise dimensions are achieved, but polymer damage occurs and structural performance deteriorates
Solution Approach 1:
The patent forms the final lug geometry and fiber orientations during the composite manufacturing process itself, before curing. The plies are wrapped and positioned to achieve the desired shape and structural properties, eliminating the need for post-fabrication machining that would damage the polymer matrix and compromise structural integrity.
Data Source
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.