Fiber Composite Joint Reinforcement with Anchored Metal Foil
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Solution Overview
Problem
Fiber composite components in aircraft and spacecraft are prone to in-plane damage such as delamination, which existing bonding technologies struggle to effectively prevent, especially under high loads and accidental impacts, due to limitations in damage tolerance and surface roughness affecting fatigue strength.
Innovation Solution
Incorporating a metal foil with anchoring sections as a transverse reinforcement element between the fiber composite component and the structural component, where the metal foil protrudes from the surface and extends through both components to provide additional anchoring and prevent delamination, using methods like stamping, bending, or additive layer manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bonding technologies are used to connect fiber composite components, then the connection strength is improved, but the damage tolerance against delamination deteriorates
Solution Approach 1:
The invention uses a hybrid connection arrangement combining metallic reinforcement elements (foils, pins, or meshes) with fiber composite materials to create a composite structure that leverages the strengths of both materials - the metal provides damage tolerance and delamination resistance while the composite provides lightweight strength
Solution Approach 2:
The metallic reinforcement elements are applied locally at critical connection zones and joint areas where delamination risk is highest, rather than uniformly across the entire component, providing targeted damage tolerance enhancement where needed most
2Reliability
If transverse reinforcements are added to prevent delamination, then the damage tolerance is improved, but the weight increases
Solution Approach 1:
Metallic reinforcements are strategically placed only at critical connection zones and joint areas where delamination risk is highest, rather than uniformly across the entire component, providing targeted damage tolerance enhancement with minimal additional weight
Solution Approach 2:
The invention employs thin metallic foils and meshes as reinforcement elements that provide effective delamination resistance while minimizing weight addition, utilizing the high strength-to-weight ratio of metallic materials in thin-form configurations
3Reliability
If metallic reinforcements are used between fiber composite components, then the delamination resistance is improved, but the manufacturing complexity increases
Solution Approach 1:
Metallic reinforcement elements are pre-formed and positioned within the fiber composite layup before curing, allowing the reinforcement structure to be integrated into the component during the initial manufacturing process rather than requiring separate post-processing steps
Solution Approach 2:
The invention combines the metallic reinforcement elements with the fiber composite manufacturing process, integrating multiple functions (structural strength, delamination resistance, and reinforcement) into a single unified component rather than assembling separate parts
Data Source
Figure 1a~1c
Figure 2~4
Figure 5~6
AI summary
The invention relates to a method for connecting a fiber composite component (2) to a structural component (3) of an air and spacecraft, wherein a metal foil (4) is provided between the fiber composite component (2) and the structural component (3) as a transverse reinforcement element. Said foil is designed having at least one anchoring segment (7) protruding from the surface (9) facing the fiber composite component (2), and inserted between the fiber composite component (2) and the structural component (3). A corresponding arrangement is produced according to said method.