Composite Connecting Rod with Metal Inserts for Impact Strength
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Solution Overview
Problem
Existing side brace rods for aircraft undercarriages face challenges in reducing weight while maintaining impact strength, as metal endpieces dominate the rod's weight and provide insufficient impact strength when replaced with composite materials.
Innovation Solution
A method of fabricating a composite material rod with reinforced ends using a mandrel, braiding fibers around it, and injecting polymer resin to create a cohesive rod body with solid inserts for enhanced impact strength, reducing weight and aerodynamic noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal endpieces are used in composite material rods, then impact strength is improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining carbon fiber reinforced plastic for the rod body with metal inserts at the ends. This hybrid approach allows the lightweight composite material to be used where weight reduction is critical, while metal inserts provide the necessary impact strength at the endpieces, resolving the contradiction between weight reduction and impact strength requirements.
Solution Approach 2:
The patent implements local quality by using different materials in different parts of the rod: composite material for the main body and metal inserts for the endpieces. This localized material selection optimizes the rod by applying metal only where impact strength is critical (at the ends) while using lightweight composite material for the bulk of the rod, thereby reducing overall weight while maintaining necessary strength.
2Weight of moving object
If thin-walled tubular portions are used, then weight is reduced, but impact strength deteriorates
Solution Approach 1:
The patent uses composite materials (carbon fiber reinforced plastic) for the thin-walled tubular portions, which provide high strength-to-weight ratio. The composite material allows thin-walled construction that maintains adequate impact strength through the inherent strength of the carbon fiber reinforcement, while reducing weight compared to solid metal construction.
Solution Approach 2:
The patent applies local quality by concentrating material thickness and strength where needed: the endpieces have thicker construction with metal inserts for impact strength, while the central tubular portion can be thinner-walled since it primarily provides structural support and weight reduction, optimizing the balance between weight and strength.
3Weight of moving object
If composite material is used throughout the rod, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent segments the rod into distinct parts with different material compositions: a composite material body and separate metal inserts for the endpieces. This segmentation allows each part to be manufactured using optimized processes for its specific material requirements, simplifying the overall manufacturing compared to producing a fully composite rod with complex endpiece reinforcements, while still achieving weight reduction.
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
The method results in a lightweight rod with improved impact strength and a smooth, aerodynamically favorable shape, effectively addressing the weight and strength limitations of previous designs.
Implementation Method 1
injecting and polymerizing resin into the layers(s) of braided fibers in order to establish cohesion rigidly bonding the layers of braided fibers and at least the ends of the mandrel together
Data Source
AI summary
In the field of aviation, a method of fabricating a composite-material rod. The method comprises a first step of fabricating a mandrel comprising a sleeve of composite material and solid inserts of composite material secured to the ends of said sleeve to constitute a rigid whole. Then, one or more layers of braided fibers are applied around the mandrel by using a fiber-braiding machine. Next, a resin is injected into the layers of braided fibers so as to establish cohesion rigidly bonding the braided fiber layers and at least the ends of the mandrel in order to form a rod body out of composite material having reinforced ends. Finally, respective holes are drilled at each end of the rod body, each hole passing through the layers of braided fibers and also through the corresponding insert.