Composite Aircraft Frame Jig RTM Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing aircraft load frames using machined metal structures result in long assembly times and excessive weight due to the need for riveted sections, which are not optimized for weight or precision.
Innovation Solution
A jig and method utilizing RTM technology to create composite material frames with integrated C-shaped and L-shaped sections, stabilization ribs, and roving fiber preforms, allowing for injection and curing processes that reduce assembly time and weight by using a repetitive process with short curing cycles, achieving high dimensional precision and controlled thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If machined metal structures or shaped sheet metal structures with riveted sections are used to manufacture aircraft load frames, then structural strength and rigidity are achieved, but the final weight is much greater than desired and assembly times are long
Solution Approach 1:
The patent merges multiple separate metal sections (Z-section and brackets) into a single integrated composite frame structure. By using RTM technology to manufacture the entire frame as one piece with embedded reinforcement elements, the need for riveted connections is eliminated, reducing both weight and assembly complexity while maintaining structural strength
Solution Approach 2:
The patent employs composite materials (fiber-reinforced polymers) instead of traditional machined metal structures. The composite material allows for integrated manufacturing of complex geometries with embedded reinforcement elements, achieving high strength-to-weight ratio and eliminating the need for separate metal reinforcement parts and riveted joints
2Strength
If machined metal structures with riveted sections are used to manufacture aircraft load frames, then structural strength is achieved, but assembly times are long
Solution Approach 1:
The patent combines multiple manufacturing operations into a single RTM process step. The frame, stabilization ribs, and reinforcement elements are all manufactured integrally in one curing cycle, eliminating the sequential assembly and riveting operations required by traditional metal structure manufacturing
Solution Approach 2:
The reinforcement elements and stabilization ribs are pre-positioned within the mold cavity before resin injection, allowing them to be integrated into the final structure during the curing process. This preliminary placement eliminates the need for post-manufacturing assembly operations
3Ease of manufacture
If traditional preform manufacturing processes are used, then frame sections can be manufactured, but surface finish precision and dimensional control are insufficient
Solution Approach 1:
The patent replaces traditional mechanical machining and assembly processes with RTM technology. The resin injection process naturally fills and conforms to the mold cavity, providing inherent dimensional accuracy and surface finish without requiring subsequent machining operations, while still allowing for complex integrated geometries
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 manufacture of lightweight, complex, and rigid composite material frames with improved surface finish and dimensional control, reducing manufacturing time and weight while maintaining structural integrity.
Implementation Method 1
injection and curing processes, of composite material frame preforms for aircraft fuselages by using RTM (resin transfer molding) technology
Data Source
AI summary
The present invention relates to a jig for the manufacture, by means of injection and curing processes, of preforms of composite material frames for aircraft fuselages by using the RTM (resin transfer molding) technology. Two preforms are thus manufactured, one with a C shaped section and another with a L shaped section, together with the preforms of the stabilization ribs for stabilizing the web of the frames and the preform of the roving or staple fiber to cover the gap between the C shaped preform and the L shaped preform. Theses preforms are previously manufactured by any known process for manufacturing preforms. According to a second aspect, the present invention relates to a method of manufacturing composite material load frames for aircraft.