Hybrid Contoured Washer for Sine-Wave Beam Load Spreading
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Solution Overview
Problem
Conventional radius-filling washers are inefficient in transmitting bolt loads to composite floor beam webs in seat track attachment assemblies, particularly in 'sine-wave' configurations, due to corrosion issues and inability to nest properly, and are not structurally optimal for distributing loads effectively.
Innovation Solution
A hybrid contoured load-spreading washer with a composite layer and a bonded metal layer, designed to fit the contour of the floor beam web, allowing efficient load distribution and transmission of forces without increasing the thickness of the floor beam web, using a triangular shape with a concave gap that conforms to the web ridge and a fastener opening for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional monolithic metal washers are used, then load spreading is achieved, but corrosion issues arise and they cannot nest with sine-wave web configurations
Solution Approach 1:
The washer uses a composite construction with a composite material layer (corrosion-resistant) bonded to a metal layer (structurally strong). This allows the washer to resist corrosion while maintaining load-spreading capability and adaptability to sine-wave web configurations through the composite layer's flexibility and contourability.
Solution Approach 2:
The washer is divided into distinct layers: a composite material layer and a metal layer. Each layer performs its specialized function - the composite layer provides corrosion resistance and contour adaptability, while the metal layer provides structural strength for load spreading.
2Strength
If local thickness increase is used to strengthen seat track connections, then load-carrying capability is enhanced, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of increasing thickness throughout the entire seat track or floor beam, the solution applies a localized load-spreading washer at the critical bolted connection point. This concentrates the strengthening effect exactly where needed, maintaining overall structural efficiency while avoiding unnecessary material and manufacturing complexity.
3Stress or pressure
If conventional radius-filling washers are used, then load distribution is achieved, but structural efficiency is limited due to inability to nest with sine-wave configurations
Solution Approach 1:
The washer design changes the geometric parameters of the load-spreading surface to match the sine-wave contour of the web. The composite layer can be formed with varying thickness and contour to nest into the wave valleys, maximizing the load-distribution area across the undulating surface rather than just contacting the peaks.
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 hybrid washer effectively distributes primary bolt loads over a larger area of the floor beam web, enhancing load-carrying capacity and reducing the need for increased thickness or weight, while avoiding corrosion issues by using composite and titanium materials.
Implementation Method 1
a washer body having a composite layer and a metal layer bonded to the composite layer
Data Source
AI summary
A hybrid contoured load-spreading washer is disclosed. An illustrative embodiment of the washer includes a washer body having a composite layer and a metal layer bonded to the composite layer and a fastener opening extending through the washer body. A floor beam seat track attachment assembly and a method of transmitting a load from a seat track to a floor beam web in a seat track attachment assembly are also disclosed.