Hybrid Tension-Compression Joint for Bonded Composite Members

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Solution Overview

Problem

Joining composite structural members is challenging due to the fibrous and laminated nature of composite materials, which disrupts load paths and reduces mechanical properties, leading to weight increase and reduced structural efficiency.

Innovation Solution

A structural joint design featuring tailored compression elements, adhesive materials, and a joint cover body with internal pockets and securing devices that distribute compressive forces evenly across adhesives, maintaining efficient load paths and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If drilling holes through composite structures to join members, then mechanical joining is achieved, but load paths are disrupted and mechanical properties degrade

Engineering Contradiction:

Improvemechanical propertiesVSAvoidjoining difficulty

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent replaces traditional mechanical joining methods (drilling, fasteners) with an adhesive bonding system. The adhesive material is applied between the composite structural members and cured to form a strong bond, eliminating the need to drill holes through the composite materials and thereby preserving the integrity of the load paths and mechanical properties.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The adhesive material serves as an intermediary substance between the composite structural members. It facilitates the joining function without requiring direct mechanical contact or penetration of the composite materials, thus maintaining their structural integrity while achieving effective load transfer between members.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If using adhesive materials to join composite members, then load paths are maintained, but joint complexity increases

Engineering Contradiction:

Improveload path efficiencyVSAvoidjoint structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The joint assembly is segmented into distinct functional components: compression elements (separators) that maintain spacing and align members, adhesive material that provides bonding, and optional reinforcement elements. This segmentation allows each component to perform its specific function optimally while keeping the overall design manageable and systematic.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The compression elements are designed with specific geometric parameters (thickness, profile shape, material properties) that can be adjusted to control the gap between members, distribute compressive forces evenly, and accommodate variations in manufacturing tolerances. This parametric design approach simplifies the joining process by making the system adaptable to different requirements.

Inventive Principle:

Principle #35Parameter changes

3Stress or pressure

If using compression elements with tailored geometry, then force distribution is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveforce distributionVSAvoidcompression element fabrication

Core Design Contradiction:

Stress or pressureVSEase of manufacture

Solution Approach 1:

The compression elements are designed with tailored geometric parameters (profile shape, thickness, surface area distribution) that can be adjusted to optimize force distribution across the adhesive joint. These parametric variations allow the same basic component type to be manufactured using standard processes while achieving different performance characteristics as needed.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The compression elements may be manufactured from composite materials or material composites (such as fiber-reinforced polymers) that provide the necessary mechanical properties (compressive strength, stiffness) while allowing for complex geometries to be formed through composite manufacturing processes like molding or filament winding.

Inventive Principle:

Principle #40Composite materials

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 effectively joins composite structural members while maintaining mechanical properties and reducing weight, enhancing structural efficiency by evenly distributing loads and reinforcing the joint with tailored geometry and adhesives.

Implementation Method 1

a first adhesive material covering the external profile geometry of the first compression element and filling the gap between the first structural member and the first compression element

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11231060B2Hybrid tension/transverse compression structural joint

Publication Date: 2022.01.25 MCFALL BRUCE DANIEL

AI summary

A structural joint includes a first compression element and a second compression element. The first and second compression elements each define an exterior profile geometry tailored to accommodate a set of loading conditions. A first structural member with a distal end portion is disposed adjacent the first compression element and a first gap is defined therebetween, and a second structural member with a distal end portion is disposed adjacent the second compression element and a second gap is defined therebetween. A first adhesive fills the first gap and a second adhesive fills the second gap. A joint cover body extends over the distal end portions of the first and second structural members.