Co-Cured Composite Inserts for Aircraft Routing Support
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Solution Overview
Problem
The complex routing and maintenance of hydraulic and electric systems in aircraft are costly and time-consuming, requiring numerous supports and fittings, and are challenging in areas with limited access, while traditional structures are heavy and require extensive maintenance.
Innovation Solution
A composite structure with integrated inserts, featuring a core and composite strip arrangement co-cured with the aircraft structure, which includes through-holes for metal bushes to support and attach external routings, reducing the need for additional supports and simplifying installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional external supports are used for routing installation, then the structure can support hydraulic and electric systems, but the weight increases and manufacturing time extends
Solution Approach 1:
The patent merges the support function with the composite structure itself by integrating inserts directly into the structure during manufacturing. The inserts are embedded within the composite material, eliminating the need for separate external supports and reducing overall weight while maintaining structural integrity for routing installation.
Solution Approach 2:
The inserts are manufactured and integrated into the composite structure during the initial manufacturing process rather than being installed later. This preliminary integration reduces subsequent assembly steps, shortens manufacturing time, and eliminates the need for separate support installation in hard-to-reach areas.
2Ease of operation
If multiple separate supports are installed for routing, then the systems can be properly supported, but the installation time and maintenance tasks increase
Solution Approach 1:
Multiple support functions are merged into a single integrated insert structure that can accommodate multiple routing paths. This consolidation reduces the number of separate installation operations needed and simplifies maintenance activities by providing unified access points.
Solution Approach 2:
The integrated inserts are designed with universal functionality to support various routing configurations within a single component. The inserts can accommodate different routing arrangements and are designed to be accessible from multiple directions, making them suitable for various installation scenarios without requiring multiple specialized supports.
3Strength
If external supports are added to the structure, then routing installation is enabled, but the structural load capacity is reduced
Solution Approach 1:
The support capability is merged into the load-bearing composite structure itself rather than being added as separate external elements. The inserts are structurally integrated and designed to bear loads without compromising the overall strength of the composite structure, enabling routing support while maintaining load capacity.
4Productivity
If traditional manufacturing processes are used without integrated inserts, then the composite structure can be manufactured, but additional maintenance downtime is required
Solution Approach 1:
The inserts are pre-integrated into the composite structure during manufacturing, with pathways and access points prepared in advance. This preliminary preparation eliminates the need for subsequent drilling, cutting, or modification operations during maintenance, reducing downtime and improving ease of repair.
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 solution reduces manufacturing time and costs, minimizes weight, and enhances load-bearing capacity while simplifying installation and maintenance, particularly in restricted areas, by integrating the inserts directly into the composite structure.
Implementation Method 1
a composite strip arrangement formed by a first section, surrounding the core and attached to said core by an adhesive polymeric layer
Implementation Method 2
which can be manufactured in one-shot, that is, with only one curing cycle
Data Source
Figure 1~2
Figure 3~5
Figure 6a~6b
AI summary
Composite structure (1) for an aircraft, having at least one insert (2) for receiving attachment devices, each insert (2) comprising a core (3) having a mayor dimension and containing at least one through-hole (4), and a composite strip arrangement formed by a first section (5) surrounding the core (3) and attached to said core (3) by an adhesive polymeric layer, and a second section (6) comprising at least one free end (6a). The first (5) and the second portion (6) of the composite strip arrangement are disposed over a first surface (1a) of the composite structure (1), such that the mayor dimension of the core (3) is positioned transversal to said first surface (1a). The at least one insert (2) is co-cured with the composite structure (1).