Flexible Composite Joint for Engine Mounting
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Solution Overview
Problem
Existing composite materials with sheet-like reinforcement components face challenges in achieving low stiffness while maintaining high strength-to-weight ratios, particularly in applications like aircraft engine and inlet mounting, where relative motion causes sealing issues and durability problems due to the use of rubber seals, which add weight and are prone to wear.
Innovation Solution
A composite part with a flexible section is created by layering fabric material supported by a flexible elastomer between laminated sections of reinforcement material, eliminating the need for fasteners and allowing for structural incorporation without weight penalties, using a process that involves forming pre-melded composite sections and a flexible section, which are then melded together.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If rubber seals are used to accommodate relative motion between engine and inlet, then sealing is achieved, but weight increases and durability decreases due to wear
Solution Approach 1:
The patent changes the material parameter from rigid rubber seals to a flexible composite section with elastomeric matrix and fabric reinforcement, altering the physical and mechanical properties to achieve both flexibility for sealing and high strength for durability, eliminating the weight penalty of traditional rubber seals
Solution Approach 2:
The patent uses a composite material consisting of fabric reinforcement (such as carbon fiber, glass fiber, or aramid fabric) embedded in an elastomeric matrix, combining the flexibility needed for sealing with the high strength and low weight characteristics of fiber-reinforced composites, thereby resolving the contradiction between durability and weight
2Reliability
If mounting features are added to accommodate relative motion, then sealing is improved, but weight penalty increases
Solution Approach 1:
The patent merges the sealing function and the structural mounting function into a single integrated flexible composite section, eliminating the need for separate mounting features and seals, thereby achieving improved sealing performance without additional weight penalty
Solution Approach 2:
The flexible composite section serves multiple functions simultaneously: it provides sealing accommodation for relative motion, acts as a structural mounting feature, and maintains the high strength-to-weight ratio of composite materials, thereby resolving the contradiction between sealing performance and weight
3Strength
If traditional composite materials are used, then high strength and stiffness to weight ratio is achieved, but low stiffness cannot be obtained
Solution Approach 1:
The patent changes the matrix material parameter from rigid thermosetting or thermoplastic polymers to elastomeric materials, fundamentally altering the stiffness parameter while maintaining the high strength-to-weight ratio through fabric reinforcement, thereby enabling low stiffness applications
Solution Approach 2:
The patent applies local quality by using fabric reinforcement specifically in regions requiring strength while allowing the elastomeric matrix to provide flexibility and low stiffness, creating a composite with spatially varying properties that simultaneously achieves high strength-to-weight ratio and low overall stiffness
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 solution provides a lightweight, durable, and structurally integrated compliant joint that reduces the load on the composite part, enhancing its performance by minimizing the need for additional mounting features and improving sealing by accommodating relative motion without sacrificing stiffness or strength.
Implementation Method 1
a flexible composite section joins the first composite section to the second composite section. The flexible composite includes multiple layers of a fabric material supported by a flexible elastomer
Data Source
AI summary
A composite part includes a first composite section and a second composite section connected by a flexible section. The first composite section has a laminated structure including multiple layers of reinforcement material supported by a matrix material. The second composite section has a laminated structure including multiple layers of reinforcement material supported by a matrix material, and a flexible composite section joins the first composite section to the second composite section. The flexible composite includes multiple layers of a fabric material supported by a flexible elastomer. The multiple layers of the fabric material overlap with the first composite section and the second composite section by being layered in between at least a portion of the multiple layers of reinforcement material forming the laminated structures of the first composite section and the second composite section.