Composite Pressure Bulkhead Splice Angles
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Solution Overview
Problem
The manufacturing and installation of aircraft pressure bulkheads are complex, time-consuming, and labor-intensive due to the use of multiple materials and assemblies, which complicates the process and increases costs, especially when dealing with dissimilar materials like metal and composite materials, and limits automation in drilling holes for joint assembly.
Innovation Solution
A pressure bulkhead system that uses composite materials for all components, including skin splice angles and stringer splice angles, to integrate two joints with a single type of part, eliminating the need for multiple assemblies and allowing automated drilling from the outside, reducing the number of parts and processes required, and providing a fail-safe configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple assemblies and machined parts are used to reinforce the pressure bulkhead joint, then the structural strength and certification requirements are met, but the weight and complexity of the joint increase significantly
Solution Approach 1:
The patent combines multiple separate reinforcement components (stringer splice fittings, chord splice fittings, outer break rings, and skin splice angles) into a single integrated pressure bulkhead joint assembly. This unified structure maintains all necessary structural functions while eliminating the complexity of assembling and coordinating multiple separate parts.
Solution Approach 2:
The integrated pressure bulkhead joint assembly performs multiple structural functions simultaneously: it reinforces the bulkhead, splices stringers, splices chords, provides outer break protection, and seals skin joints. This multi-functional design eliminates the need for separate dedicated components for each function.
2Reliability
If multiple assemblies and different material types are used in the pressure bulkhead joint, then the structural requirements and certification standards are satisfied, but the manufacturing time and labor hours increase considerably
Solution Approach 1:
The patent integrates multiple assembly operations into a single manufacturing process. By combining the stringer splice fittings, chord splice fittings, outer break rings, and skin splice angles into one pre-assembled unit, the patent eliminates multiple separate assembly steps, reducing manufacturing time and labor requirements while maintaining structural reliability.
3Strength
If heavily reinforced joint configurations with multiple parts are used, then the structural integrity and certification requirements are met, but the weight of the pressure bulkhead assembly increases more than desired
Solution Approach 1:
The patent consolidates multiple reinforcement elements into a single optimized joint assembly structure. This integration allows for more efficient material distribution and reduces redundant material usage while maintaining all necessary structural strengths for certification.
Data Source
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AI summary
The illustrative embodiments disclose a pressure bulkhead system comprising an aft pressure bulkhead, skin splice angles, and stringer splice angles. The aft pressure bulkhead has an outer compression ring. The skin splice angles are positioned adjacent to one another and joined to the outer compression ring. The skin splice angles form a joint between a first section of a fuselage, a second section of the fuselage, and the aft pressure bulkhead. The stringer splice angles join the skin splice angles to a stringer in the second section of the fuselage.