Positive-Locking Rod Composite Joints Using Heated Sleeve Forming
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Solution Overview
Problem
Existing methods for producing positive-locking load applications for rod-shaped fiber composite structures, such as tension-compression rods, face high manufacturing costs due to the use of injection molding and magnetic forming, which are not economically viable for small lots.
Innovation Solution
A method involving a fiber plastic hollow structure with undercuts, where the structure is locally heated and an outer sleeve made of plastic or metallic material is applied, creating a positive-locking connection through wrapping or forming, allowing for a cost-effective and precise connection without the need for complex molds or magnetic forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If injection molding method is used to produce positive-locking load application, then manufacturing precision is improved, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent replaces the injection molding process with a mechanical assembly process. Instead of using complex injection molding equipment to create the positive-locking connection, the invention uses a force application element with an undercut geometry that mechanically interlocks with the fiber plastic hollow structure. This mechanical interlocking approach eliminates the need for expensive injection molding equipment while achieving the same connection precision.
Solution Approach 2:
The patent extracts the essential function of the positive-locking connection from the complex injection molding process. By identifying that the core requirement is a mechanical interlock, the invention separates this function from the expensive molding process and implements it through a simpler force application element with an undercut that can be assembled mechanically.
2Strength
If magnetic forming is used to compress the integral connection, then strength is improved, but device complexity increases and manufacturing cost increases
Solution Approach 1:
The patent replaces magnetic forming equipment with a simple mechanical compression process. Instead of using complex magnetic fields to compress and bond the connection, the invention employs a force application element with an undercut geometry that creates a mechanical interlock. This mechanical approach achieves the required connection strength without requiring expensive magnetic forming equipment.
3Ease of manufacture
If thermoplastic matrix is used instead of thermoset matrix, then manufacturing cost is reduced and ease of manufacture is improved, but manufacturing precision may be affected
Solution Approach 1:
The patent changes the material parameter from thermoset to thermoplastic matrix, which allows for lower manufacturing costs and easier processing. The thermoplastic material can be heated and formed more easily, enabling the mechanical assembly process to achieve the required precision without the complexity of injection molding. The undercut geometry of the force application element ensures precise positioning regardless of the matrix type.
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
This method reduces manufacturing costs and enables the production of high-strength, lightweight tension-compression rods with improved buckling resistance and tensile strength, suitable for aerospace applications, while maintaining a positive-locking connection.
Implementation Method 1
locally heating the fiber plastic hollow structure to the point of plasticity of the fiber plastic hollow structure
Implementation Method 2
locally heating the fiber plastic hollow structure to the point of plasticity of the fiber plastic hollow structure, in particular in the region of the undercut(s) of the force application element
Data Source
AI summary
Disclosed are methods and related compositions for producing a positive-locking load application for rod-shaped fiber composite structures, and the design thereof.The present invention concerns a method for producing a positive-locking load application for tension-compression rods from a fiber plastic hollow structure by means of an outer sleeve. In this process, a force pushes the fiber plastic hollow structure at least partially over at least one force application element, which is provided with at least one undercut to create a positive-locking connection. An object of the present invention is attained through local heating of the fiber plastic hollow structure to the point of plasticity of the fiber plastic hollow structure, at least in the region of the undercut(s) of the force application element, and application of at least one outer sleeve to the fiber plastic hollow structure in the region of the force application element.