Embedded Mechanical Features in Composite Structures

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Solution Overview

Problem

Fiber-reinforced composite structures face challenges in integrating mechanical features without compromising structural integrity, as conventional methods like drilling for fasteners weaken the material and traditional bonding methods are rarely used in structural applications due to weight and load-bearing limitations.

Innovation Solution

A method involving the use of pressurizable members with recessed regions to embed mechanical features within complex-shaped composite structures, applying counteracting pressures to minimize weight and ensure load-carrying capabilities, while using autoclave or oven techniques to prevent buckling and distortion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If mechanical features are integrated using drilled and assembled fastener patterns, then mechanical attachment is achieved, but fiber cutting and compressive strength loss occur resulting in additional parasitic weight

Engineering Contradiction:

Improvemechanical attachment capabilityVSAvoidparasitic weight

Core Design Contradiction:

Ease of manufactureVSWeight of moving object

Solution Approach 1:

The patent merges the mechanical feature integration process with the composite manufacturing process by embedding mechanical features during autoclave curing. This combines two separate operations (drilling/assembly and composite fabrication) into one, eliminating the need for post-manufacturing drilling and fastener installation, thereby reducing parasitic weight while maintaining mechanical attachment capability

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies preliminary action by positioning and embedding mechanical features into the composite structure before the resin cures. The mechanical features are placed in their final positions within the mold during the layup stage, and the autoclave process simultaneously cures the resin and sets the mechanical features in place, preventing subsequent drilling and assembly operations

Inventive Principle:

Principle #10Preliminary action

2Weight of moving object

If mechanical features are embedded during composite manufacturing, then parasitic weight is reduced, but manufacturing complexity increases

Engineering Contradiction:

Improveparasitic weightVSAvoidmanufacturing process complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The patent uses the autoclave process as an intermediary that simultaneously performs multiple functions: curing the resin, applying compressive pressure to eliminate voids, and setting the mechanical features in their embedded positions. This single intermediary process manages the complexity of embedding mechanical features without requiring separate operations for each function

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The autoclave manufacturing process is made multi-functional by using it to simultaneously cure the composite resin, embed mechanical features, apply compressive pressure to minimize voids, and establish the final structural geometry. This universal process handles multiple tasks that would otherwise require separate operations, reducing overall manufacturing complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If counteracting pressures are applied during autoclave process, then voids are minimized and structural integrity is improved, but process complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies counteracting pressures during the autoclave process where internal pressure from the autoclave counteracts the weight and settling of the composite layup and mechanical features. This counter-pressure prevents void formation and ensures proper resin distribution, improving structural integrity while the autoclave process manages the complexity of pressure application

Inventive Principle:

Principle #8Anti-weight (Counterweight)

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 allows for the creation of lightweight, structurally sound composite structures with embedded mechanical features that maintain load-carrying capabilities and minimize voids, reducing parasitic weight and enhancing the reliability of composite components.

Implementation Method 1

providing an internal pressure to the pressurizable members... providing an external pressure to the assembly to form the composite structure, wherein the internal and external pressures operate to compress the fiber plies around the mechanical feature while substantially minimizing voids

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS11235542B2Composite structures having embedded mechanical features

Publication Date: 2022.02.01 VISION COMPOSITE PROD LLC

AI summary

A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with mechanical features embedded or encapsulated therein. The mechanical features may be located on or at least partially between two or more pressurizable members, which may be internally pressurized within a mold. The mechanical features may operate as bearing plates, attachment fittings, or other structural elements. Assemblies of pressurizable members, fiber plies and mechanical features may be arranged to create complex composite structures with predefined load paths, enhanced structural capability or both.