Composite Assembly Pad Protrusion Insertion
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Solution Overview
Problem
The insertion of metallic projections into laminates of fibre plies requires high forces, potentially causing damage and can be hindered by complex geometries, leading to restricted access.
Innovation Solution
A composite assembly is created by bonding a pad of fibre plies impregnated with a pad matrix material to a laminate, with protrusions from a part penetrating the fibre plies, using methods like stepped lap or scarf joints, and optionally embedding the pad within the laminate, to reduce insertion forces and facilitate access.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If metallic projections are pressed directly into a laminate of fibre plies, then the protrusions are inserted into the laminate, but the insertion force required is very high which can damage the laminate and access is restricted if the laminate is geometrically complex
Solution Approach 1:
A pad of fibre plies is introduced as an intermediary layer between the metallic protrusions and the laminate. The protrusions are first pressed into the pad (which has lower density and is easier to penetrate), and then the pad with embedded protrusions is bonded to the laminate. This mediator approach reduces the insertion force required and avoids direct high-force contact with the laminate structure.
Solution Approach 2:
The protrusions are pressed into the pad before the pad is bonded to the laminate. This preliminary action allows the protrusions to be embedded in a more compliant material (the pad) under lower force conditions, and subsequent bonding to the laminate locks them in place without requiring high insertion forces into the laminate itself.
2Reliability
If metallic projections are pressed directly into a laminate of fibre plies, then the protrusions are inserted into the laminate, but the high insertion force can damage the laminate
Solution Approach 1:
The pad acts as a protective intermediary that absorbs the insertion force. By pressing protrusions into the pad rather than directly into the laminate, the laminate structure is protected from damage. The pad's more compliant nature allows force absorption without compromising laminate integrity.
Solution Approach 2:
The protrusions are embedded in the pad before bonding to the laminate. This preliminary embedding in a softer material prevents direct high-force impact on the laminate, ensuring the laminate remains undamaged while still achieving secure protrusion placement through subsequent bonding.
3Adaptability or versatility
If the laminate has complex geometry, then the design can accommodate complex shapes, but access to the laminate is restricted making insertion difficult
Solution Approach 1:
The pad serves as an accessible intermediary that can be positioned and manipulated more easily than the complex laminate itself. Protrusions are inserted into the pad from the accessible side, and the pad is then bonded to the complex geometry of the laminate, eliminating the need for direct access to the laminate's complex surfaces.
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
This approach reduces the risk of damage to the laminate during insertion and allows for efficient integration of protrusions, enhancing the manufacturing process by minimizing force requirements and accommodating complex geometries.
Implementation Method 1
pressing the protrusions into a pad of fibre plies so that the protrusions penetrate at least some of the fibre plies of the pad
Implementation Method 2
curing a pad matrix material impregnating the pad, and bonding the pad to a laminate of fibre plies impregnated with a laminate matrix material
Data Source
AI summary
A composite assembly with a laminate of fibre plies impregnated with a laminate matrix material is disclosed having pad of fibre plies impregnated with a pad matrix material, and a part with a body with protrusions which extend from the body and penetrate at least some of the fibre plies of the pad. The pad is bonded to the laminate by a stepped lap joint or a scarf joint. The assembly is manufactured by pressing the protrusions into the pad, and after the protrusions have been pressed into the pad, curing a pad matrix material impregnating the pad, and bonding the pad to the laminate.