Braided Thermoplastic Composite Tubes for Lightweight Aircraft Ducts
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Solution Overview
Problem
Existing composite materials used in aircraft components, such as air ventilation ducts, are labor-intensive to manufacture, expensive, and often too heavy due to their thermoset composition, while thermoplastic alternatives still require significant labor and may not be light enough.
Innovation Solution
A composite material comprising braided fiber tape strips made of unidirectional fibers embedded in a thermoplastic matrix, optionally with a thermoplastic film inside to fill voids and provide support, allowing for the creation of lightweight tubular parts with reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermoset composite materials are used to manufacture aircraft parts, then the parts meet fire, smoke and toxicity requirements, but the manufacturing process is labor intensive and expensive
Solution Approach 1:
The patent changes the material parameter from thermoset to thermoplastic composite materials. This parameter change maintains fire safety compliance while enabling automated manufacturing processes that reduce labor intensity and production costs.
Solution Approach 2:
The patent uses composite materials made of thermoplastic matrix combined with reinforcing fibers (such as glass, carbon, or aramid fibers). This composite structure maintains the mechanical strength and fire resistance required for aircraft applications while allowing for more efficient manufacturing methods.
2Strength
If thermoset composite materials are used, then the parts meet structural requirements, but the parts are relatively heavy
Solution Approach 1:
The patent changes the material composition parameter by using thermoplastic matrices instead of thermoset matrices. This parameter change results in lighter parts while maintaining the required structural strength through optimized fiber reinforcement.
Solution Approach 2:
The patent employs composite materials with thermoplastic matrices and reinforcing fibers to achieve an optimal strength-to-weight ratio. The composite structure provides the necessary structural strength while significantly reducing part weight compared to traditional thermoset composites.
3Weight of moving object
If thermoplastic sheets are used to manufacture parts, then the parts are lighter, but the manufacturing process still requires significant labor
Solution Approach 1:
The patent replaces manual mechanical manufacturing operations with automated processing methods. The thermoplastic composite material can be processed through automated forming and bonding equipment, eliminating the need for manual cutting, heating, and assembly operations.
Solution Approach 2:
The patent changes the material state parameter by utilizing the thermoplastic material's ability to be heated and formed in a single continuous process. This parameter change enables automated manufacturing equipment to shape and bond parts without manual intervention, reducing labor intensity while maintaining light weight.
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 enables the production of lighter, less labor-intensive composite parts that meet stringent requirements for aircraft components, such as ventilation ducts, by minimizing reinforcement and using a thermoplastic matrix for bonding and support, thereby reducing weight and manufacturing effort.
Implementation Method 1
Each of the plurality of fiber tape strips is made of a single layer of unidirectional fibers. The fibers are at least partially embedded in a thermoplastic matrix.
Implementation Method 2
pressurizing a film inside a tube made from a composite material while heating both the tube and the film up to their forming temperature so as to bond the film to a plurality of braided fiber tape strips
Data Source
AI summary
A composite material comprising a plurality of fiber tape strips woven or braided together. Each of the plurality of fiber tape strips is made of a single layer of unidirectional fibers. The fibers are at least partially embedded in a thermoplastic matrix. A tubular composite part is made from this composite material and of an internal film. A method of manufacturing the composite material comprises weaving or braiding the fiber tape strips, especially in the form of a tube. A method of manufacturing a composite part comprises pressurizing the film inside the tube while heating both the tube and the film up to their forming temperature so as to bond the film to the woven fiber tape strips.