Composite Rod Joints Using Deformed Metal Collars
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Solution Overview
Problem
The existing 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 due to complex machining and sensitive supply chain requirements.
Innovation Solution
The method involves applying internal and external metal collars to the 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 allows for easy connection with off-the-shelf hardware.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If expensive and heavy metallic joints with complex shapes are used to join composite rods, then the structural integrity and load-bearing capacity are improved, but the weight and manufacturing cost increase significantly
Solution Approach 1:
The joint system is divided into separate components: a simpler metallic joint body and deformation collars that are applied to the composite rod ends. This segmentation allows the metallic joint to have a simple, standardized geometry while the collars provide the deformation-based connection, reducing the overall complexity and weight of the metallic components.
Solution Approach 2:
The collars undergo parameter changes through plastic deformation when subjected to unidirectional compressive loading. This deformation transforms the collars from a preliminary state (before deformation) to a final state (after deformation) where they are mechanically interlocked with the composite rod, creating a strong connection without requiring complex metallic joint geometry.
2Strength
If complex-shaped monolithic metallic parts are used for joints, then the load-bearing capacity is improved, but the manufacturing complexity and labor costs increase
Solution Approach 1:
The joint system is divided into separate components: a simpler metallic joint body and deformation collars that are applied to the composite rod ends. This segmentation allows the metallic joint to have a simple, standardized geometry while the collars provide the deformation-based connection, reducing the overall complexity and weight of the metallic components.
Solution Approach 2:
The deformation collars serve as sacrificial or consumable components that are deformed to create the connection. Rather than requiring expensive, complex metallic joints, the system uses simpler collars that undergo permanent deformation to achieve the bonding function, significantly reducing manufacturing costs and complexity.
3Reliability
If advance planning and supply chain sensitivity are increased for complex metallic joints, then the joint performance is optimized, but the production flexibility and responsiveness decrease
Solution Approach 1:
The metallic joint body is designed with universal, standardized geometry that can accommodate different collar configurations and composite rod specifications. This universality allows the same basic joint design to be used across multiple applications, reducing the need for custom-designed joints and improving supply chain flexibility and production responsiveness.
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
Data Source
AI summary
A method for joining composite rods with tubular shape 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.