Composite Barrel Sections for Aircraft Fuselages
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Solution Overview
Problem
Current methods for manufacturing composite fuselage sections for aircraft are labor-intensive and require extensive tooling, limiting their application to smaller aircraft, while larger commercial aircraft primarily use metallic materials due to the challenges in scaling composite manufacturing processes.
Innovation Solution
The development of composite barrel sections with a skin formed by fiber tows or tapes applied to a mandrel, along with stiffeners that are cocured or adhesively bonded, allowing for the creation of continuous cylindrical structures that can be joined to form a complete fuselage shell, reducing manufacturing complexity and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional composite manufacturing methods are used, then lightweight high-strength composite fuselage sections can be produced, but the process becomes labor-intensive and requires extensive tooling
Solution Approach 1:
The fuselage is divided into modular barrel sections that can be manufactured separately using standardized composite construction methods, then assembled together. This segmentation allows each section to be produced with reduced tooling complexity while maintaining the overall lightweight structure.
Solution Approach 2:
The manufacturing process transitions from traditional metal forming parameters to composite material parameters, utilizing fiber reinforcement and resin matrix properties to achieve high strength-to-weight ratios. This parameter change enables lightweight construction without requiring complex tooling.
2Weight of moving object
If conventional composite manufacturing methods are used, then lightweight high-strength composite fuselage sections can be produced, but manufacturing costs increase
Solution Approach 1:
By segmenting the fuselage into standardized barrel sections, the patent enables batch production and reduces tooling costs. The modular approach allows for more efficient manufacturing processes and lower overall production costs compared to custom-forming entire fuselages.
Solution Approach 2:
The use of composite materials (fiber reinforcement with resin matrix) provides high strength-to-weight ratios that reduce the need for extensive structural reinforcement, thereby lowering manufacturing costs while maintaining lightweight construction.
3Weight of moving object
If composite materials are used for larger aircraft, then weight reduction is achieved, but manufacturing complexity increases
Solution Approach 1:
Larger aircraft fuselages are constructed from multiple standardized barrel sections, simplifying the manufacturing process by allowing modular production and assembly rather than requiring complex one-piece fabrication. This segmentation reduces manufacturing complexity while achieving weight reduction.
Solution Approach 2:
The barrel section design serves multiple functions: structural containment, weight reduction, and standardized assembly interface. This multi-functionality reduces manufacturing complexity by eliminating the need for specialized tooling for each function.
4Productivity
If metallic materials are used for commercial aircraft fuselages, then manufacturing scalability is maintained, but weight reduction is limited
Solution Approach 1:
The patent changes the material parameter from metal to composite, utilizing the superior strength-to-weight ratio of composite materials to reduce fuselage weight while maintaining manufacturing scalability through standardized barrel section construction methods.
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 enables the efficient production of lightweight, high-strength composite fuselage sections that can be scaled for larger aircraft, reducing weight and manufacturing costs while maintaining structural integrity.
Implementation Method 1
The carbon fibers are preimpregnated with a thermoset epoxy resin
Implementation Method 2
Following oven or autoclave curing of the resin
Implementation Method 3
The first stiffener can have a first flange portion bonded to an interior surface of the skin
Implementation Method 4
Following oven or autoclave curing of the resin
Data Source
AI summary
Composite sections for aircraft fuselages and methods and systems for manufacturing such sections are disclosed herein. A composite section configured in accordance with one embodiment of the invention includes a skin and at least first and second stiffeners. The skin can include a plurality of unidirectional fibers forming a continuous surface extending 360 degrees about an axis. The first stiffener can include a first flange portion bonded to an interior surface of the skin and a first raised portion projecting inwardly and away from the interior surface of the skin. The second stiffener can include a second flange portion bonded to the interior surface of the skin and a second raised portion projecting inwardly and away from the interior surface of the skin. A method for manufacturing a section of a fuselage in accordance with one embodiment of the invention includes positioning a plurality of uncured stiffeners on a mandrel assembly. The method can further include applying a plurality of fiber tows around the plurality of uncured stiffeners on the mandrel assembly.