Composite Track Beam Lug Structure for High-Load Weight Reduction
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Solution Overview
Problem
Conventional thrust reverser track beams made of solid metal are heavy due to increased engine diameters and bypass ratios, and existing composite track beams face structural load challenges due to weaker interlaminar properties compared to in-plane properties of composite materials.
Innovation Solution
A composite lug design for track beams featuring continuous fibers integrated within flanges and supports, formed from thermoplastic materials, which are co-cured with the longitudinal panel to enhance structural strength and stability, allowing for unitary components with attachment features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If solid metal track beams are used to support increased engine weight, then structural strength is improved, but weight increases
Solution Approach 1:
The patent applies composite materials by integrating continuous fibers (such as carbon fiber) into the lug structure and bonding it to the track beam. This composite construction provides high strength-to-weight ratio, maintaining structural strength while reducing overall weight compared to solid metal beams. The continuous fibers carry loads efficiently, compensating for the lower density of composite materials.
Solution Approach 2:
The track beam system is segmented into distinct components: the track beam itself and separate lugs that are bonded to it. This segmentation allows each component to be optimized independently - the track beam can be designed for overall structural support while lugs are designed specifically for attachment points with continuous fiber reinforcement to handle concentrated loads.
2Weight of stationary object
If composite materials are used for track beams to reduce weight, then weight is reduced, but interlaminar strength becomes insufficient for high structural loads
Solution Approach 1:
The patent uses composite materials with continuous fibers (such as carbon fiber reinforced polymers) that provide both weight reduction and enhanced strength. The continuous fiber orientation is specifically designed to carry high structural loads, and the fiber-reinforced composite structure provides superior interlaminar properties compared to conventional composite materials.
Solution Approach 2:
The lug structure incorporates localized reinforcement with continuous fibers at critical stress points where high structural loads are applied. This local quality enhancement ensures that areas subject to high stresses have superior interlaminar strength, while other areas of the track beam maintain the weight-saving composite construction.
3Ease of manufacture
If lugs are attached on the same side of the track beam as the component, then attachment is simplified, but structural efficiency is reduced
Solution Approach 1:
The lug is designed to attach to the track beam from the opposite side, utilizing the third dimension (depth/thickness of the beam) rather than attempting to attach from the same side. This dimensional approach allows the continuous fibers in the lug to extend through the track beam thickness, creating a more efficient load path that passes through the beam rather than relying on surface-level attachment.
Data Source
AI summary
A thrust reverser for a nacelle may comprise a composite track beam and a composite lug. The composite lug may be inserted through a through-hole in the composite track beam. Continuous fibers in the composite lug may provide strength in the in-plane direction.