Composite Part Convex Connection for Force Transmission
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Solution Overview
Problem
Composite materials face challenges in transmitting forces at connection areas, particularly when subjected to varying pulling and compression forces, due to the weakness of the thermoplastic or thermosetting matrix, leading to stress and strength issues at junctions with inserts.
Innovation Solution
A method involving winding fibers to form a composite part with an externally convex rounded area, placing an insert with a concave and convex face, and continuing to wind fibers to cover the insert while leaving the attachment point accessible, allowing for effective force transmission and integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If an insert is placed in the connection area to transmit forces, then the force transmission capability is improved, but the stress concentration and strength at the junction between the composite part and insert deteriorate
Solution Approach 1:
The patent applies spheroidality by creating a convex rounded area at the connection location instead of a flat or sharp transition. This curved geometry distributes the applied forces more evenly across the connection area, reducing stress concentration at the junction between the composite part and the insert, thereby maintaining strength while enabling force transmission
2Strength
If fibers are oriented according to the direction of forces in the main portion, then the strength in the main portion is improved, but the force transmission at connection areas deteriorates
Solution Approach 1:
The patent applies local quality by differentiating the fiber orientation and structure in different regions of the composite part. In the main portion, fibers are oriented to withstand axial loads, while at the connection areas, the fiber arrangement is modified to follow the contours of the convex rounded area and accommodate the insert, ensuring optimal force transmission locally without compromising the overall structural strength
3Ease of manufacture
If the connection area is designed with simple geometry, then the manufacturing ease is improved, but the force transmission and strength at connection points deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-forming the convex rounded area at the connection location during the composite molding process, before the insert is installed. This pre-shaping creates an optimized geometry for force distribution that would be difficult to achieve through post-processing, thereby maintaining manufacturing efficiency while significantly improving the strength and force transmission capability at the connection point
Data Source
AI summary
The invention relates to a method for manufacturing a composite part intended for being subjected, via at least one attachment point, to pulling and/or compression forces. The method includes: winding fibers on a hub so as to form a portion of the wall of the part, and creating an externally convex rounded area at the location intended to form the area for applying the pulling and/or compression forces. The forces are radial thereto. The method also includes placing an insert on the convex rounded area, the insert including the attachment point or a mechanism for rigidly connecting the attachment point, and continuing to wind fibers so as to form the rest of the wall, while covering a portion of the insert and leaving the attachment point or the mechanism for rigidly connecting the attachment point accessible.