Composite Pressure Hull Joint Layout for Lightweight Strength
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Solution Overview
Problem
Conventional composite pressure hulls face challenges in reducing weight while maintaining structural efficiency, particularly in applications like aircraft components, where weight affects performance and buoyancy is desirable for submersible applications.
Innovation Solution
The method involves forming a composite pressure hull by laying up unitary halves with dome and cylindrical portions on a mandrel, creating a joint transition region using scarf joints or staggered ply splices, and joining these halves to form a continuous, closed structure without central holes, utilizing composite materials and automated fiber layup techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional composite pressure hulls are manufactured using traditional methods, then structural integrity can be maintained, but weight reduction is limited and manufacturing complexity increases
Solution Approach 1:
The pressure hull is divided into two unitary halves (first half and second half), each manufactured separately using automated fiber layup techniques. This segmentation enables weight optimization through composite materials while managing manufacturing complexity by breaking down the overall structure into manageable sections that can be produced using standardized processes.
Solution Approach 2:
The patent employs composite materials consisting of reinforcing fibers bound in polymer resin matrix to construct the pressure hull halves. These composite materials provide superior strength-to-weight ratio compared to conventional materials, achieving weight reduction while maintaining structural integrity. The automated fiber layup process further enhances efficiency in manufacturing these composite structures.
2Strength
If unitary halves are joined to form a complete pressure hull, then buoyancy and structural efficiency are improved, but manufacturing precision requirements increase
Solution Approach 1:
The transition regions with joints are formed during the layup process itself, before the final curing and joining stages. This preliminary formation of joints within the transition regions allows for better integration and alignment of the unitary halves, reducing the precision demands on subsequent joining operations while maintaining structural efficiency.
Solution Approach 2:
The patent incorporates transition regions with joints at specific locations where the dome portion meets the cylindrical portion of each unitary half. These localized joint regions are designed with specific structural characteristics to handle stress concentrations, allowing the overall structure to achieve high structural efficiency while concentrating manufacturing precision requirements to specific manageable areas rather than the entire hull.
Data Source
AI summary
A composite pressure hull and methods of forming the composite pressure hull are presented. A unitary first half of the composite pressure hull is laid up. A unitary second half of the composite pressure hull is laid up. The unitary first half is joined to the unitary second half to form the composite pressure hull.