Aircraft Cargo Floor Module Manufacturing
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Solution Overview
Problem
The challenge lies in creating a cargo hold floor for aircraft that balances stability and low weight while being waterproof and fireproof, with simplified manufacturing and assembly processes to avoid complexity and high costs.
Innovation Solution
A method involving cutting recesses in a foam or structural core, arranging fiber layers with carbon, aramid, or glass fibers, inserting frame parts for functional elements like transport ball holders, and curing a synthetic resin under pressure to form a hybrid composite material floor module with integrated inserts and drainage systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional multi-step manufacturing processes are used for floor modules, then manufacturing precision can be maintained, but device complexity and production time increase significantly
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated process. Functional elements (drainage channels, recesses, fastening structures) are molded directly into the floor module during the same curing process that forms the composite material structure, eliminating separate assembly steps and reducing overall complexity.
Solution Approach 2:
Functional elements such as drainage channels and recesses are pre-formed within the floor module structure during the initial molding process. This preliminary action eliminates the need for subsequent assembly operations, as components are already in their final positions when the module is completed.
2Adaptability or versatility
If functional elements are added as separate components, then functionality is achieved, but assembly complexity and production time increase
Solution Approach 1:
The patent merges functional elements (drainage channels, recesses for fasteners, structural reinforcements) directly into the floor module during the composite material curing process. This integration eliminates the need to manufacture and assemble separate components, significantly improving production efficiency while maintaining full functionality.
Solution Approach 2:
The floor module is designed as a multi-functional integrated structure that simultaneously provides structural support, drainage functionality, fastening capabilities, and waterproofing. This universal design achieves multiple functions in a single component rather than requiring separate specialized parts.
3Strength
If high resin content is used in fiber layers, then bonding strength to core increases, but final product weight increases
Solution Approach 1:
The patent optimizes the resin content parameter within a specific range (40-50% by mass) to achieve the optimal balance between bonding strength and weight. This parameter change ensures sufficient adhesion to the core material while minimizing the weight contribution from the resin matrix.
Solution Approach 2:
The patent uses a composite material system combining fiber layers (carbon, aramid, or glass fibers) with a polymeric resin matrix. This composite structure provides high strength-to-weight ratio, where the fibers carry the primary load while the resin provides bonding and structural continuity, achieving both strength and lightness.
4Productivity
If curing temperature is increased to accelerate the process, then production time decreases, but energy consumption and risk of damage increase
Solution Approach 1:
The patent specifies an optimized curing temperature range (60-200°C) that balances curing speed with material safety. This parameter optimization allows sufficient cross-linking and bonding to occur while preventing thermal degradation of the fiber layers or core material, achieving fast curing without harmful effects.
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 approach results in a lightweight, stable, and functional cargo deck with integrated functional elements, reduced complexity in manufacturing, and enhanced sealing and drainage capabilities, ensuring efficient and cost-effective production and installation.
Implementation Method 1
curing, preferably under pressure, an applied synthetic resin such that the fiber layers and the frame parts are glued to the core
Implementation Method 2
the fiber layers and the frame parts are glued to the core
Implementation Method 3
curing, preferably under pressure, an applied synthetic resin
Implementation Method 4
curing can take place simultaneously under pressure, e.g., in a press. Preferably, a pressure of between 60 and 100 N/cm 2
Data Source
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AI summary
The present invention relates to a method for manufacturing a floor module (20, 20') for a cargo deck of an aircraft, comprising the steps of: a) cutting out recesses from a core (25), wherein the core is a foam and/or a structural core; b) arranging the core (25) between first fiber layers and second fiber layers, wherein the fiber layers comprise carbon and/or aramid and/or glass fibers such that the fiber layers project beyond the core at the sides to form an edge region; c) arranging frame parts (51, 52) in the recesses to manufacture inserts (50), preferably for receiving transport balls (56); d) curing, preferably under pressure, an applied synthetic resin such that the fiber layers and the frame parts (51, 52) are bonded to the core (25).