Composite Structural Members with Polymer Core and Metal Reinforcement
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Solution Overview
Problem
Conventional structural members, particularly in aircraft, are heavy, expensive to fabricate, difficult to inspect and repair, and lack a favorable flexural strength-to-weight ratio.
Innovation Solution
A composite structural member comprising a central reinforced polymer-based material with angled reinforcing fibers and coupled reinforcement members, using fasteners or z-pins for assembly and reinforcement, allowing for efficient fabrication, assembly, inspection, and repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural members are fabricated from aluminum or titanium to resist high flexural loads, then flexural strength is improved, but weight increases substantially
Solution Approach 1:
The patent applies composite materials by combining a reinforced polymer-based central structural portion with metal reinforcement members (such as aluminum or titanium channels, angles, or I-beams) fixedly coupled to its sides. This composite construction leverages the high strength-to-weight ratio of metals for reinforcement while utilizing the lightweight characteristics of the polymer core, thereby achieving improved flexural strength without substantially increasing overall weight.
2Weight of moving object
If reinforced polymer-based materials are used to reduce weight, then weight is reduced, but manufacturing cost and fabrication complexity increase
Solution Approach 1:
The patent segments the structural member into distinct components: a central reinforced polymer-based portion and separate metal reinforcement members. This segmentation allows each component to be manufactured independently using optimized processes (polymer molding for the core, conventional metal fabrication for reinforcements), thereby reducing overall fabrication complexity and cost compared to monolithic composite construction.
Solution Approach 2:
The patent merges the lightweight polymer-based structural portion with metal reinforcement members through fixed coupling (such as welding, mechanical fastening, or adhesive bonding). This combination achieves weight reduction benefits of polymers while incorporating the ease of manufacture and structural performance of metal components, resolving the contradiction between weight reduction and manufacturing simplicity.
3Ease of repair
If metallic structural members are used, then ease of repair and inspection is improved, but weight and manufacturing cost increase
Solution Approach 1:
By segmenting the structural member into a polymer core and metal reinforcement components, the patent enables targeted repair strategies. Damaged metal reinforcement members can be individually replaced or repaired using conventional metal repair techniques, while the lightweight polymer core maintains its integrity. This segmentation preserves the ease of repair associated with metals while maintaining the weight advantages of polymer-based structures.
Data Source
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AI summary
Composite structural members and methods for forming the same are disclosed. In one disclosed embodiment, a composite structural member (10) includes a central structural portion (16) comprised of a reinforced, polymer-based material and having a length, a first side and an opposing second side extending along the length. A first reinforcement member (12) fixedly coupled to the first side and a second reinforcement member (14) fixedly coupled to the second side.