Composite Fuselage Panel Opening Reinforcement

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Solution Overview

Problem

Aircraft fuselage panels made of composite materials face challenges in providing adequate mechanical resistance at openings while minimizing weight and size, as sudden thickness variations lead to peeling forces and stress concentration zones, which can result in rupture risks.

Innovation Solution

The introduction of a doubler made of composite material, secured to the reinforced skin portion, which combines with the integrated reinforcement to provide enhanced mechanical strength and stress distribution, eliminating the need for fold releases and reducing mass and size penalties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If an integrated reinforcement is provided at the opening contour with sufficient thickness and surface area to distribute stresses, then mechanical resistance is improved, but sudden thickness variation causes peeling forces that reduce structural integrity

Engineering Contradiction:
Improvemechanical resistanceVSAvoidpeeling forces
Core Design Contradiction:
StrengthVSObject-affected harmful factors

Solution Approach 1:

The integrated reinforcement is divided into multiple plies (first ply, second ply, third ply) with different orientations and functions. The first ply provides baseline reinforcement, the second ply adds stress distribution capability, and the third ply enhances peeling resistance. This segmentation allows each layer to contribute specifically to counteracting different stress components, thereby maintaining mechanical resistance while reducing harmful peeling forces through distributed load bearing across multiple interfaces.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The reinforcement structure uses composite material construction with multiple plies oriented at different angles (0°, 45°, 90°) to create an anisotropic structure optimized for complex stress states. This composite approach allows tailoring the mechanical properties in different directions, providing both the necessary thickness for stress distribution and the architectural complexity needed to mitigate peeling forces through inter-laminar load transfer.

Inventive Principle:
Principle #40Composite materials

2Strength

If the integrated reinforcement has a large surface area to correctly distribute stresses, then mechanical resistance is improved, but mass and size penalties increase

Engineering Contradiction:
Improvemechanical resistanceVSAvoidmass
Core Design Contradiction:
StrengthVSWeight of moving object

Solution Approach 1:

The reinforcement plies are strategically positioned and oriented only where needed around the opening contour rather than providing uniform reinforcement across the entire panel. The first ply is concentrated at the opening contour for stress distribution, while the second and third plies are positioned to specifically address peeling forces. This localized quality approach provides adequate mechanical resistance at the critical opening region without adding unnecessary mass to the entire fuselage panel.

Inventive Principle:
Principle #3Local quality

Solution Approach 2:

Instead of providing uniform reinforcement across the entire panel surface, the invention applies reinforcement plies partially only at and around the opening contour where stress concentration occurs. This partial action principle allows the structure to achieve sufficient mechanical resistance at the critical location without the mass penalty of full-panel reinforcement, accepting that reinforcement is excessive only where absolutely necessary for safety.

Inventive Principle:
Principle #16Partial or excessive action

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 design achieves necessary mechanical resistance with reduced peeling forces and optimized mass and size, ensuring effective stress distribution and minimizing the risk of rupture at openings.

Implementation Method 1

consolidation members each crossing at least partly said doubler and at least partly said reinforced skin portion

Methodology Applied
Scientific EffectMechanical Fastening: Mechanical Fastener

Data Source

PatentEP2300315B1Reinforced aircraft fuselage panel and method of manufacture
Publication Date: 2013.10.23 AIRBUS OPERATIONS (SAS)
  • EP2300315B1 patent drawingFigure 1
  • EP2300315B1 patent drawingFigure 2
  • EP2300315B1 patent drawingFigure 3

AI summary

The invention relates to a fuselage panel (30) made of composite comprising a skin (31) having an opening (40) of which at least part of the contour is reinforced by an in-built composite reinforcement. According to the invention, the said fuselage panel comprises at least one liner (60) made of composite secured to and superposed on the  said reinforced skin portion (32) and at least partially contributing to defining the contour (41) of the opening (40), the said panel (30) further comprising consolidating members (70) each passing at least partially through the said liner (60) and at least partially through the said reinforced skin portion (32). FIGURE 5