Composite Rod Collar Jointing Without Machined Connectors

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Solution Overview

Problem

Composite support structures, such as those in aircraft seats, face challenges with heavy and expensive metallic joints that require complex machining and sensitive supply chain management, compromising structural integrity and increasing costs.

Innovation Solution

The method involves applying internal and external collars to composite rods and deforming them via a unidirectional compressive load using a clamp, creating a plastic interlock that supports both compressive and tensile loads without the need for expensive machining, and allowing easy connection with off-the-shelf hardware.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional metallic joints are used to connect composite rods, then the structural integrity is maintained, but the weight and cost increase significantly

Engineering Contradiction:

Improvestructural integrityVSAvoidjoint weight

Core Design Contradiction:

StrengthVSWeight of stationary object

Solution Approach 1:

The joint system is divided into multiple functional components: an internal collar that fits inside the composite rod, an external collar that wraps around the rod, and a deformation clamp. This segmentation allows each component to perform a specific function while collectively achieving both structural integrity and weight reduction compared to traditional monolithic metallic joints

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The solution uses a hybrid composite structure combining metal collars with composite rod materials. The metal collars provide strength and deformation capability, while the composite rod maintains its lightweight properties. This composite approach allows the joint to achieve metallic strength characteristics without the full weight penalty of traditional metallic connections

Inventive Principle:

Principle #40Composite materials

2Strength

If complex machined metallic connectors are used, then the joining strength is sufficient, but the manufacturing cost and complexity increase

Engineering Contradiction:

Improvejoining strengthVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The invention changes the manufacturing parameter from complex precision machining to simple deformation processes. The collars are formed by applying compressive loads that plastically deform the metal into the desired interlocking shape, eliminating the need for expensive CNC machining, tooling, and quality control procedures associated with traditional machined connectors

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The deformation clamp serves multiple functions: it positions the collars, applies the deformation force, and creates the interlocking geometry all in one operation. The process is self-contained and does not require separate machining, assembly, or finishing operations, dramatically simplifying manufacturing

Inventive Principle:

Principle #25Self-service

3Reliability

If traditional metallic joints are used, then the connection reliability is ensured, but the supply chain complexity and lead time increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidsupply chain lead time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The collar and clamp assembly serves multiple functions: it provides structural connection, enables deformation-based joining, and creates interlocking geometry. This multi-functionality in a simple design reduces the number of specialized components needed, simplifying the supply chain and reducing lead times compared to traditional specialized machined connectors

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If composite rods are joined without metal collars, then the fabrication cost decreases, but the structural integrity and load-bearing capacity are compromised

Engineering Contradiction:

Improvefabrication costVSAvoidload-bearing capacity

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The metal collars are simple, inexpensive components that are deformed and permanently installed in the joint. Their low material cost and simple formation process make them economically viable, providing the necessary strength enhancement without the high cost of traditional machined connectors while maintaining load-bearing capacity

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 fabrication costs and time, maintains structural integrity, and simplifies the joining process, making it suitable for mass production and reducing reliance on complex supply chains.

Implementation Method 1

The resulting plastic deformation of the metal collars and composite rod interlock those components to support both compressive and tensile loads

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Data Source

PatentUS20240326350A1Metal composite joints for composite rods

Publication Date: 2024.10.03 BE AEROSPACE INC

AI summary

A method for joining composite rods with tubular shape without expensive, machined connectors and without compromising the structural integrity of the composite rod includes internal and external collars applied to the ends of the composite rod and deformed via unidirectional compressive load applied by a clamp in the radial direction of the composite rod cross-section. The resulting plastic deformation of the metal collars and composite rod interlock those components to support both compressive and tensile loads. The deformed metal collars are easily joinable to other components via off-the-shelf hardware.