Compressible Mounting System for Composite Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for mounting objects to composite structures, such as vehicle bodies, are costly, heavy, and inefficient due to the need for extensive composite hard points and large metal structural members, and lack control over compression, resulting in poor attachment strength.
Innovation Solution
A mounting system that includes a compressible structure with boss holes and interior and exterior plates, where the interior plate has bosses protruding into the compressible structure, allowing for controlled compression and reduced thickness between the plates, facilitating secure attachment of objects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional composite hard points and large metal structural members are used for mounting, then attachment strength is achieved, but weight and manufacturing cost increase significantly
Solution Approach 1:
The patent changes the physical state of the composite material by introducing controlled compressibility through core material selection and layer configuration. This allows the composite structure to deform elastically under load, distributing stresses more effectively and achieving strong attachments without requiring heavy metal reinforcement members.
Solution Approach 2:
The patent utilizes composite material construction with alternating layers of composite material and core material of different densities. This layered composite structure provides both the necessary strength for mounting attachments and the compressibility needed to reduce stress concentrations, eliminating the need for heavy metal structural members while maintaining attachment strength.
2Adaptability or versatility
If extensive composite hard points are formed in the composite structure, then mounting capability is provided, but manufacturing complexity and cost increase
Solution Approach 1:
The patent segments the mounting function from the main composite structure by using through-thickness boss holes that extend completely through the laminate. This allows attachments to be mounted at multiple locations without requiring extensive hard points in each area, as the boss holes provide standardized mounting locations throughout the structure, simplifying the manufacturing process.
Solution Approach 2:
The through-thickness boss holes serve multiple functions: they provide mounting locations for attachments, facilitate compression control during assembly, and enable load distribution across the composite structure. This multi-functionality reduces the need for specialized hard points at each mounting location, thereby reducing manufacturing complexity.
3Strength
If bonding agent is used to fill uncontrolled gaps in conventional mounting, then attachment is achieved, but the bonding agent is adversely affected by being in the load path
Solution Approach 1:
The patent introduces compression-controlled core material as an intermediary between the attachment and the composite structure. This core material absorbs and distributes compressive loads through elastic deformation, preventing the bonding agent from being directly in the load path. The intermediary core material protects the bonding agent from adverse stress conditions while maintaining strong attachment.
Solution Approach 2:
The patent changes the load path parameters by controlling the compression of the core material during assembly. By pre-compressing the core material to a predetermined amount, the system ensures that loads are transmitted through the compressed core rather than through the bonding agent, thereby protecting the bonding agent from being adversely affected by direct load path stresses.
4Ease of operation
If compression of the composite is not controlled in conventional mounting, then assembly is simplified, but attachment strength deteriorates
Solution Approach 1:
The patent applies preliminary compression to the core material during the assembly process by using boss holes that extend through the entire thickness of the composite. This pre-compression is built into the design through the predetermined boss hole depth and core material thickness, ensuring that the composite is compressed to the optimal amount before the attachment is fully secured, thereby achieving strong interface attachment without complex assembly procedures.
Solution Approach 2:
The patent incorporates feedback mechanisms through the boss hole design where the depth and positioning of the boss holes provide inherent feedback on the compression amount. As the attachment is assembled, the compression of the core material is automatically controlled by the boss hole geometry, ensuring that the composite is compressed to the predetermined optimal amount without requiring external measurement or adjustment, thus maintaining both assembly simplicity and attachment strength.
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 system provides a stronger, lighter, and more cost-effective attachment method by controlling compression and distributing load effectively, enhancing the strength and precision of the mounting interface.
Implementation Method 1
the compressible structure is compressed a predetermined amount as a function of a length of the boss
Implementation Method 2
The strength of the attachment is affected because the bonding agent is typically directly in the load path
Data Source
AI summary
A mounting system including a compressible structure having a first surface, a second surface, and at least one boss hole extending through the compressible structure from the first surface to the second surface. The system further including an interior plate mounted on the first surface of the compressible structure, wherein the interior plate includes a boss protruding from the interior plate and into the boss hole of the compressible structure, and an exterior plate mounted on the second surface of the compressible structure and secured to the interior plate against the boss of the interior plate, wherein the compressible structure is compressed a predetermined amount as a function of a length of the boss.