Composite Rod Joints Using Deformed Metal Collars
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Solution Overview
Problem
Conventional methods for joining composite rods in support structures, such as aircraft seats, require expensive and heavy metallic joints that compromise structural integrity and are costly to manufacture, with complex shapes requiring advanced planning and labor-intensive machining.
Innovation Solution
A method involving the application of internal and external metal collars to composite rods, which are deformed via unidirectional compressive load using a clamp to interlock the components, allowing for easy connection with off-the-shelf hardware and supporting both compressive and tensile loads without compromising the structural integrity of the composite rods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional metallic joints are used to join composite rods, then the joint can support compressive and tensile loads, but the joint becomes heavy and expensive with complex shapes requiring considerable labor
Solution Approach 1:
The joint is divided into two separate components: a metal collar and a composite rod section. The metal collar is fitted around the composite rod and deformable to create an interlocking connection, eliminating the need for heavy monolithic metallic joints while maintaining load support capability
Solution Approach 2:
The joint utilizes a hybrid composite structure combining metal (collar) and composite materials (rod). This composite approach leverages the strength of metal for load-bearing while maintaining the weight advantages of composite materials, reducing overall joint weight compared to conventional all-metal joints
2Strength
If conventional metallic joints with complex shapes are used, then the joint can support loads, but the manufacturing cost and labor increase significantly
Solution Approach 1:
The joint is divided into two separate components: a metal collar and a composite rod section. The metal collar is fitted around the composite rod and deformable to create an interlocking connection, eliminating the need for heavy monolithic metallic joints while maintaining load support capability
Solution Approach 2:
The metal collar is designed to undergo plastic deformation during assembly, changing its shape from a simple cylindrical form to an interlocking configuration. This parameter change allows the collar to mechanically lock with the composite rod without requiring complex machining operations, significantly reducing manufacturing cost and labor
3Strength
If monolithic metallic parts with complex shapes are used, then the joint can support loads, but the machining process becomes expensive and time-consuming
Solution Approach 1:
The joint is divided into two separate components: a metal collar and a composite rod section. The metal collar is fitted around the composite rod and deformable to create an interlocking connection, eliminating the need for heavy monolithic metallic joints while maintaining load support capability
Solution Approach 2:
The metal collar is designed to undergo plastic deformation during assembly, changing its shape from a simple cylindrical form to an interlocking configuration. This parameter change allows the collar to mechanically lock with the composite rod without requiring complex machining operations, significantly reducing manufacturing cost and labor
4Ease of manufacture
If conventional metallic joints are used, then the joint can be fabricated, but the fabrication process requires significant advance planning and sensitivity to supply chains
Solution Approach 1:
The metal collar is designed as a universal component that can be used with various composite rod dimensions and configurations. The collar's deformable nature allows it to adapt to different rod sizes, eliminating the need for custom-designed joints for each application and reducing supply chain complexity
Solution Approach 2:
The metal collar is pre-formed with a simple cylindrical shape that facilitates easy assembly. The deformation process occurs during assembly itself, eliminating the need for advance planning of complex machining operations and reducing sensitivity to supply chain timing
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 solution reduces fabrication costs and time, eliminates the need for expensive machining, and simplifies the joining process, enabling mass production and reducing weight while maintaining structural integrity, thus addressing the limitations of traditional metallic joint methods.
Implementation Method 1
The resulting plastic deformation of the metal collars and composite rod interlock those components
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method for joining composite rods (200) with tubular shape without expensive, machined connectors and without compromising the structural integrity of the composite rod includes internal and external collars (202, 304) 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. The method for securing joint components to a composite rod comprises: inserting an internal collar (202) into an end of the composite rod (200); placing an external collar (304) over the end of the composite rod; placing a clamp device (306, 308) around the end of the composite rode over the external collar; and deforming the internal collar, the external collar, and the end of the composite rod via applying unidirectional compressive load in the radial direction to the clamp device.