Overbraided Composite Duct Assembly for Complex Aircraft Geometries
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Solution Overview
Problem
Existing duct structures for aircraft propulsion systems face challenges in manufacturing efficiency and structural integrity, particularly in forming complex geometries and ensuring robust connections between duct sections.
Innovation Solution
A method for manufacturing a fiber-reinforced composite duct structure involves forming tubular sidewalls from woven fiber sleeves over mandrels, infusing polymer material, and assembling the duct sections with precise alignment and attachment techniques, such as welding or mechanical fastening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional duct structures are used for aircraft propulsion systems, then manufacturing simplicity is maintained, but structural integrity and ability to achieve complex geometries deteriorate
Solution Approach 1:
The duct structure is divided into multiple modular sections that can be formed separately using woven fiber sleeves and then assembled together. This segmentation allows each section to be manufactured with high structural integrity while enabling complex overall geometries through modular assembly, resolving the contradiction between strength and manufacturing complexity.
Solution Approach 2:
The patent employs fiber-reinforced composite materials formed by impregnating woven fiber sleeves with polymer resin. This composite material approach provides superior structural integrity and enables complex geometries that cannot be achieved with traditional materials, while the standardized forming process maintains manufacturing feasibility.
2Shape
If complex geometries are achieved in duct structures, then functional performance is improved, but manufacturing efficiency deteriorates
Solution Approach 1:
The woven fiber sleeves are pre-formed with the desired complex geometries and reinforcement patterns before resin impregnation. This preliminary action allows complex shapes to be achieved without adding manufacturing steps, as the geometric complexity is built into the sleeve structure itself rather than requiring post-forming operations.
Solution Approach 2:
The patent utilizes variations in fiber weave patterns, sleeve dimensions, and resin flow parameters to achieve complex geometries. By changing these manufacturing parameters, diverse duct shapes can be produced using the same basic forming process, maintaining manufacturing efficiency while achieving geometric complexity.
3Strength
If robust connections between duct sections are ensured, then structural integrity is improved, but assembly complexity deteriorates
Solution Approach 1:
The connection structures are merged into the duct section designs themselves, with integrated flanges, interlocking features, or continuous fiber reinforcement at joints. This merging eliminates separate connection components and simplifies assembly while ensuring robust connections, as the structural continuity is built into the duct sections rather than added through separate fastening operations.
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 method enables the production of duct structures with enhanced structural integrity, improved manufacturing efficiency, and the ability to achieve complex geometries, thereby addressing the limitations of existing technologies.
Implementation Method 1
The first woven fiber sleeve is wrapped circumferentially around the first mandrel
Implementation Method 2
disposing a polymer material with the first woven fiber sleeve
Implementation Method 3
overmolding a cellular core onto a tubular first sidewall of the first duct section
Implementation Method 4
bonding the back skin to the cellular core
Data Source
AI summary
A method is provided for manufacturing during which a first duct section is formed with a tubular first sidewall. A first opening extends through the tubular first sidewall. The forming of the first duct section includes disposing a first woven fiber sleeve over a first mandrel and disposing a polymer material with the first woven fiber sleeve. A second duct section is disposed with a tubular second sidewall. The forming of the second duct section includes disposing a second woven fiber sleeve over a second mandrel and disposing the polymer material with the second woven fiber sleeve. The second duct section is arranged with the first duct section. The second duct section engages the tubular first sidewall. The tubular second sidewall is located at and extends circumferentially around the first opening. A duct structure is formed by attaching the second duct section to the first duct section.