Fiber Composite Tension Element Connection via Metal Projections
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Solution Overview
Problem
Existing methods for connecting fiber composite tension elements to metal components are inefficient due to material incompatibility and weight issues, leading to durability and weight concerns, especially under high tensile forces.
Innovation Solution
A connection system using a force introduction element with projections on its surface, encased by a fiber composite sheathing element, which provides a form-fit and adhesive bond, allowing for better force distribution and reducing the need for heavy metal components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal end pieces are used to connect fiber composite tension elements, then connection strength is improved, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining fiber composite material with metal projections to create a hybrid connection element. The metal projections provide the necessary mechanical interlocking strength while the fiber composite material maintains low weight, resolving the contradiction between connection strength and weight.
Solution Approach 2:
The patent applies local quality by concentrating metal material only where needed - in the form of projections on the connection element's surface - rather than using solid metal throughout. This localized metal reinforcement provides connection strength only where required, minimizing overall weight while maintaining structural integrity.
2Reliability
If adhesive bonding is used to connect pultruded rods, then connection durability is improved, but the required adhesive length increases, requiring larger and heavier end pieces
Solution Approach 1:
The patent applies segmentation by dividing the connection mechanism into distinct functional elements: metal projections for mechanical interlocking and adhesive for bonding. This segmentation allows the mechanical interlocking to provide immediate structural connection while reducing the adhesive length required, thereby reducing end piece volume.
Solution Approach 2:
The patent uses adhesive as an intermediary substance that fills the spaces between metal projections and the fiber composite material, creating a bonded connection that works synergistically with the mechanical interlocking. This combination allows for shorter adhesive lengths while maintaining connection durability.
3Reliability
If integrally manufactured tension elements with fastening means are used, then connection reliability is improved, but production complexity and cost increase
Solution Approach 1:
The patent applies segmentation by separating the tension element from the connection element, allowing each to be manufactured independently using optimized processes. The fiber composite tension element can be manufactured by pultrusion or braiding, while the connection element with metal projections can be manufactured separately and then assembled, reducing production complexity compared to integral manufacturing.
4Weight of moving object
If fiber composite material is used for tension elements, then weight is reduced, but connection durability to metal components deteriorates due to material incompatibility
Solution Approach 1:
The patent applies composite materials by creating a hybrid connection structure that combines fiber composite material with metal projections. This composite approach allows the tension element to maintain its low weight while the metal projections provide compatible mechanical interlocking with the fiber composite material, resolving the durability issue.
Solution Approach 2:
The patent uses adhesive as an intermediary that chemically and mechanically bonds the fiber composite material to the metal projections. This intermediary substance bridges the material incompatibility between fiber composites and metal, ensuring durable connections while maintaining the low weight advantage of fiber composite tension elements.
Data Source
Figure 1A~1C
Figure 2~3
Figure 4A~5
AI summary
An arrangement (1) for connecting an elongate element (2), which is used for absorbing and/or transmitting tensile and/or torsional forces, to a further component (3) comprises a force introduction element (4) with a side which faces the further component (3) and a side which faces away from the further component (3), and an encasing element (5) having a closed cross section, said encasing element encasing the force introduction element (4) at least in some sections and projecting over the force introduction element (4) on its side which faces away from the further component (3). On at least one section of the force introduction element (4) projections (6) are provided on its outer surface which faces the encasing element (5), said projections at least partially penetrating the encasing element (5). The encasing element (5) is substantially composed of a fibre composite material, the fibre structure of which is produced by braiding or winding processes, wherein the fibres contained in the fibre composite material lie in continuous form at least partially in the regions formed between the projections (6). The projections (6) are present in a dense, regular arrangement at least in one region of the force introduction element (4), and the ratio of height of the projections (6) to diameter of the projections (6) is greater than 1, preferably greater than 2, in particular 3 and more.