Composite Panel Assembly with Rods and Coupling Nuts
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Solution Overview
Problem
Existing methods for constructing large-scale structures, such as ocean thermal energy conversion pipes, using composite materials are time-consuming and require expensive on-site resin transfer manufacturing equipment, necessitating a more efficient and cost-effective approach for assembling and securing pre-formed panels with interlocking seam joints and butt joints.
Innovation Solution
A method involving pre-formed panels with specific edge profiles and internal rods secured by coupling nuts, allowing for rapid assembly and interconnection of panels to form a tubular structure, utilizing pultrusion or other composite manufacturing processes, with optional inserts and reinforcement for stability and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If resin transfer molding process is used to construct large scale structures, then structural strength and compression characteristics are improved, but construction time increases and expensive on-site manufacturing equipment is required
Solution Approach 1:
The structure is divided into multiple pre-formed panel sections that can be manufactured separately and then assembled on-site. Each panel is pre-manufactured with precise dimensions and composite material properties, eliminating the need for time-consuming on-site resin transfer molding while maintaining structural integrity through standardized connection mechanisms
Solution Approach 2:
Panels are pre-formed and pre-assembled into sections before being transported to the construction site. The pre-assembly process includes attaching connection elements and ensuring proper alignment features are in place, so that on-site assembly requires only simple connection operations rather than complex manufacturing processes
2Ease of manufacture
If resin transfer molding equipment is installed on site for constructing large scale structures, then composite material structures can be built, but device complexity and cost increase
Solution Approach 1:
The complex resin transfer molding manufacturing process is extracted from the on-site construction operation and relocated to off-site manufacturing facilities. This allows the sophisticated composite material manufacturing to be performed in controlled factory environments using specialized equipment, while on-site construction is reduced to simple assembly operations with minimal equipment requirements
Solution Approach 2:
The manufacturing process is segmented into two distinct phases: complex composite material formation performed off-site in factory settings, and simple mechanical assembly performed on-site. This separation eliminates the need to transport or install expensive resin transfer molding equipment at the construction location
3Productivity
If pre-formed panels are assembled on site, then construction time is reduced, but structural strength and joint reliability may be compromised
Solution Approach 1:
Connection elements, alignment features, and surface preparation are all completed during off-site panel manufacturing. The panels arrive at the construction site ready for assembly with precision-machined connection interfaces that ensure proper alignment and structural integrity, eliminating the need for time-consuming on-site preparation work
Solution Approach 2:
The connection mechanism integrates multiple functions into a single assembly operation: alignment features guide proper positioning, mechanical connectors provide structural strength, and sealing elements ensure weather tightness. This integrated connection system allows all joint functions to be achieved in one straightforward assembly step rather than multiple separate operations
Data Source
AI summary
A large scale structure includes a plurality of panels, wherein each panel has at least one opening therethrough. And each panel has opposed edge profiles that are positionable next to adjacent panels and opposed end profiles that are positionable next to adjacent panels. A plurality of rods extend through aligned openings so as to interconnect the plurality of panels to one another. And a plurality of coupling nuts, each coupling nut attachable to an end of one of the rods, wherein the coupling nuts secure the panels to one another. An insert with apertures aligned with the openings allows a rod to extend through the insert and facilitate securement of the insert to the plurality of panels so as to form a section. Additional sections can be assembled as needed to form the structure.