DPC Connectors for Affordable Composite Structures

Acceptance of composites for aircraft is limited by manufacturing and repair costs. The lack of joining techniques tend to force composite aircraft designs into unified stress-flow structures. Unified structures preclude the economies and safety of component replacement that is the aircraft industry standard. A new family of composite connectors may enhance the future of composite aircraft. Dynamic Polymer Composite (DPC) connectors create a smooth stress flow between cylindrical structural members. DPC connectors have high-modulus fibers that are pre-stressed during manufacture to be released during assembly when the polymer matrix is heated. To assemble, tubular members are fitted into a DPC sleeve. When the sleeve is heated, it clamps the members. With pressure adhesives, full moment can be developed. DPCs are conformable and require little surface preparation. Thus, composite field repair is feasible. Opportunities exist for systems integration with reduced attenuation. Phase I includes a material survey, life cycle stress calculations, the fabrication and demonstration of a proof-of-concept DPC connector, and a technical assessment. Phase II will address application, design, manufacturing, and design impace.