Composite Rod Shell Joints for Optics Frame Load Transfer
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Solution Overview
Problem
The development of composite frames for opto-mechanical support structures faces challenges in creating structurally reliable and cost-efficient joints due to weak strength properties of composites in directions other than the fiber direction, manufacturing limitations for complex joint designs, and the limited applicability of traditional metallic joining solutions.
Innovation Solution
The implementation of a joint design that uses upper and lower shells with matching profiles to interconnect composite rods, allowing for effective load transfer and connection of opto-mechanical equipment to composite frames and larger structural systems, utilizing Automated Fiber Placement (AFP) manufacturing and various shell geometries such as X-type, T-type, K-type, and L-type joints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metallic joining solutions (welding, rivets, bolting) are used to connect composite rods, then connection strength may be improved, but applicability and structural reliability deteriorate due to composite material properties
Solution Approach 1:
The patent introduces an intermediary component (the joint structure with recesses and protrusions) that mediates between the composite rods. This intermediary enables mechanical connection without requiring direct welding or bolting of the composite materials themselves, thus maintaining connection strength while adapting to composite material properties.
Solution Approach 2:
The joint structure utilizes composite materials (metal matrix composite or ceramic matrix composite) that combine the benefits of metallic strength with compatibility for composite rod connections. This allows the joint to provide both structural strength and adaptability to connect composite rods effectively.
2Reliability
If complex joint designs are implemented to improve connection reliability, then structural reliability may be improved, but manufacturing complexity and cost increase
Solution Approach 1:
The joint is segmented into distinct functional components: a body with recesses for receiving rod ends and protrusions for interlocking. This segmentation allows each component to be manufactured separately using optimized processes, reducing overall manufacturing complexity while maintaining structural reliability.
Solution Approach 2:
The patent employs parameter changes in the form of controlled recesses and protrusions with specific geometric parameters. These parameterized features provide reliable mechanical interlocking while allowing for standardized manufacturing processes, thus achieving reliability without excessive complexity.
3Weight of moving object
If composite frames are used to reduce weight and fabrication time, then weight and manufacturing efficiency are improved, but joint strength and structural reliability deteriorate
Solution Approach 1:
The joint utilizes composite materials (metal matrix composite or ceramic matrix composite) that provide high strength-to-weight ratio, matching or exceeding the strength of traditional metallic joints while maintaining the weight reduction benefits of the composite frame structure.
Solution Approach 2:
The joint acts as an intermediary that transfers and distributes loads between composite rods, ensuring that the connection point maintains structural reliability comparable to traditional metallic structures while the overall frame benefits from composite material weight reduction.
Data Source
AI summary
A joint for a composite frame includes a first composite rod, a first shell abutting the first composite rod, a second shell abutting the first composite rod and disposed opposite the first shell relative to the first composite rod. The first and second shells are joined together such that composite rod is fixed therebetween. A method of forming joints of composite frame includes forming a composite frame by interconnecting a plurality of composite rods formed by an Automated Fiber Placement (AFP) manufacturing method around a mandrel, applying a first shell to the plurality of composite rods at a first location where composite rods are interconnected, applying a second shell at the first location opposite the first shell relative to the composite rods, and joining the first and second shells together with the composite rods at the first location disposed between the first and second shells.