Thermoplastic Tie-Rod Structure for Low-Weight, Lower-Cost Strength
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Solution Overview
Problem
Existing tie rods are either prohibitively expensive when made from thermoset composite materials or excessively heavy when constructed from metals, limiting their practicality, especially in applications requiring large quantities, such as in aircraft or structural reinforcement.
Innovation Solution
A tie rod design featuring a thermoplastic tube with tapered sections and inserts, where the inserts have a tapered body and radial fins, and a method of manufacturing that involves positioning these inserts within the tube, applying a vacuum to prevent wrinkling, and deforming fibers into channels to secure the tube, resulting in a lightweight and cost-effective structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tie rods are constructed from thermoset composite materials, then structural strength is improved, but manufacturing cost increases prohibitively
Solution Approach 1:
The patent changes the material parameter from thermoset composite to thermoplastic material, which allows for lower manufacturing cost while maintaining structural requirements. The thermoplastic material can be processed using simpler, more cost-effective methods such as injection molding, eliminating the need for expensive autoclave curing processes required for thermoset composites.
Solution Approach 2:
The patent employs a composite structure combining thermoplastic material with embedded reinforcement fibers (such as carbon fiber, glass fiber, or aramid fiber). This composite approach maintains the structural strength required for tie rod applications while using cost-effective thermoplastic matrix material and strategically placed fiber reinforcement, avoiding the high cost of full thermoset composite construction.
2Strength
If tie rods are constructed from metallic materials, then structural strength is improved, but weight increases excessively
Solution Approach 1:
The patent uses a composite material system consisting of thermoplastic matrix combined with reinforcement fibers (carbon fiber, glass fiber, or aramid fiber). This composite construction provides high strength-to-weight ratio, achieving the required structural strength while significantly reducing weight compared to solid metallic tie rods. The fiber reinforcement carries the primary loads while the thermoplastic matrix binds the fibers and distributes stresses.
Solution Approach 2:
The patent implements local fiber reinforcement within the thermoplastic structure, placing reinforcement fibers strategically in areas requiring higher strength rather than using uniform metal construction throughout. This localized quality approach optimizes weight by providing strength only where needed, rather than over-engineering the entire tie rod with heavy metal material.
3Strength
If traditional manufacturing methods are used for tie rods, then structural requirements are met, but material waste increases
Solution Approach 1:
The patent changes the manufacturing process parameter from traditional subtractive or assembly methods to injection molding of thermoplastic material. Injection molding is an additive forming process that shapes material directly into the final geometry, minimizing or eliminating material waste. The thermoplastic material can be precisely dosed and formed to match the exact tie rod geometry required, with minimal scrap generation compared to metal machining or composite layup methods.
Solution Approach 2:
This principle is not applicable to the patent as it deals with material waste reduction, not visual properties or color changes.
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, cost-effective tie rod that meets structural requirements, reducing material waste and manufacturing complexity, suitable for various applications including aircraft and structural reinforcement.
Implementation Method 1
applying a vacuum to prevent wrinkling
Data Source
AI summary
A tie rod that includes a central section, a first tapered section, and a second tapered section. A thermoplastic tube extends the length of the tie rod. The first tapered section includes a first insert positioned within the thermoplastic tube. The second tapered section includes a second insert positioned within the thermoplastic tube. A channel extends through the tie rod along the central section, the first tapered section, and the second tapered section.