FIELD

The present disclosure relates generally to lug clusters and more specifically to lug clusters for use with composite tubes.

BACKGROUND

Various types of aircraft utilize tubes such as struts including, for example, to deploy nose, body, and/or wheel landing gear systems. Conventionally, aircraft landing gear include metal tubes and structural components, for example, landing gear strut tubes. Such components are made of metallic materials and often comprise complex geometries and high strengths. However, these metallic components are typically heavy.

SUMMARY

A lug cluster is disclosed in accordance with various embodiments. The lug cluster may include a first side having a flange including a first side groove receiving a fiber filament according to a filament path, a second side having a flange including a second side groove receiving the fiber filament according to the filament path, and a saddle. The saddle may include a floor member having a planar member formed to follow a contour of a composite tube and an upper infill member resting on the floor member and positioned between the first side and the second side.

A method of manufacturing a lug cluster is disclosed in accordance with various embodiments. The method may include forming a first side having a first side including a flange with a first side groove and forming a second side having a flange with a second side groove. The first side and second side are joined together by a saddle having a floor member including a planar member shaped to follow a contour of a composite tube. The method may include wrapping a first filament along a filament path disposed along the first side groove and the second side groove, whereby the lug cluster is secured in compression against the composite tube. The method may further include consolidating the composite tube and the lug cluster by resin transfer molding and forming an upper infill member resting on the floor member and positioned between the first side and the second side. A wrap of fiber, such as a continuous wrap of fiber around the lug and tube secures the lug to the tube and reacts loads that may otherwise pull the lug from the tube.

A landing gear system is disclosed in accordance with various embodiments. The landing gear system may include a composite tube, a first lug cluster mounted to the composite tube, and a second lug cluster mounted to the composite tube. The composite tube may comprise at least one of a filament wound composite tube, a filament braided tube, and a composite tube of laid up filament. In various embodiments, the first lug cluster and the second lug cluster are oriented at an angle to one another.

