Fibre Composite Pressure Bulkhead with Modular Core Insertion
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Solution Overview
Problem
Modern aircraft pressure bulkheads made of fibre composite materials face challenges in achieving a highly integrated structure with outstanding structural mechanical properties while being efficiently manufacturable.
Innovation Solution
A pressure bulkhead design featuring a first area element with receptacles for core elements, made from fibre composite materials with multiaxial and unidirectional fibre mats, and a curable synthetic matrix, which includes a system and method for manufacturing that uses a tool with a receiving device and pressurization to integrate core elements and matrix material efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a monolithic fibre composite pressure bulkhead is used, then structural integrity is improved, but manufacturing complexity increases
Solution Approach 1:
The pressure bulkhead is divided into modular components: a monolithic fibre composite shell and separate insert elements that can be pre-manufactured and then integrated. This segmentation allows each component to be manufactured independently using optimized processes, reducing overall manufacturing complexity while maintaining structural integrity through the integrated assembly
2Weight of moving object
If fibre composite materials are used, then weight is reduced, but structural rigidity and buckling stability become difficult to achieve
Solution Approach 1:
The invention uses fibre composite materials with specifically oriented fibres arranged in multiple layers with different orientations (including 0°, 90°, and ±45° angles) to optimize both weight and structural rigidity. The composite structure is designed to provide the necessary buckling stability while maintaining low weight, resolving the contradiction between lightweight construction and structural stability
3Strength
If reinforcements are applied to stressed areas, then rigidity is improved, but manufacturing time and cost increase
Solution Approach 1:
Reinforcement areas are pre-formed as integral parts of the monolithic fibre composite shell during the initial manufacturing process, rather than being added separately afterward. This preliminary action allows reinforcements to be manufactured simultaneously with the main structure using automated fibre placement techniques, improving rigidity in stressed areas without significantly increasing manufacturing time or cost
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 provides a pressure bulkhead with enhanced structural mechanical properties, high strength, and low weight, while being cost-effective and simple to manufacture, maintaining structural integrity under varying pressures and rapid pressure changes.
Implementation Method 1
The matrix of the area elements may be formed from the matrix material by curing of an impregnation applied to the surfaces of the reinforcing fibres
Implementation Method 2
a pressurization device (41) for pressurizing the tool cavity (38)
Data Source
Figure 1~2
Figure 3~7
Figure 8~9
AI summary
A pressure bulkhead (10; 10') of fibre composite material for an aircraft fuselage (6) for the pressure-tight axial closure of a fuselage region (8) configured to be put under internal pressure comprises a first area element (14; 14'), at least one second area element (22; 22') and a plurality of core elements (16; 16'). The first area element (14; 14') has a plurality of receptacles (12; 12'). Each receptacle (12; 12') is configured to receive a core element (16; 16'). The core elements (16; 16') are received in the receptacles (12; 12') between surfaces facing one another of the first area element (14; 14') and of the at least one second area element (22; 22'). The surfaces facing one another of the first area element (14; 14') and of the at least one second area element (22; 22') are connected to one another in regions (20; 20') without core elements.