Composite Ring Frame Manufacturing via Tubular Preform Groove
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Solution Overview
Problem
The existing methods for manufacturing aircraft window frames from composite materials are complex, prone to weaknesses at junction zones, and struggle to maintain consistent fiber orientation, leading to reduced mechanical characteristics and sealing issues.
Innovation Solution
A process involving a tubular casing of dry or pre-impregnated fibers threaded onto a coaxial assembly with a peripheral groove, where the casing is forced into the groove, tightened, and joined to form a preform, which is then solidified under specific temperature and pressure conditions, allowing for a single-piece annular frame with controlled thickness and improved fiber orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple preforms are assembled and consolidated to manufacture a window frame, then the frame can be manufactured with required structural features, but the manufacturing process becomes complex and junction zones develop weaknesses
Solution Approach 1:
The invention uses a single continuous tubular preform instead of multiple separate preforms, eliminating the need for assembly operations while maintaining all required structural features including sealing zones, fixing zones, and aerodynamic surfaces in one integrated component
Solution Approach 2:
The invention combines multiple structural functions (sealing, fixing, aerodynamic surface, structural strength) into a single monolithic frame structure manufactured from one continuous preform, eliminating junction zones and associated weaknesses while reducing manufacturing process complexity
2Shape
If conventional preforming methods are used to create frame structures, then the frame shape can be achieved, but fiber orientation becomes disrupted and mechanical characteristics are reduced
Solution Approach 1:
The invention performs fiber orientation preparation in advance by creating a tubular preform with pre-established fiber directions that match the final frame's structural requirements, then directly consolidating this pre-oriented preform to maintain fiber alignment and maximize mechanical properties
Solution Approach 2:
The invention changes the physical state of the preform from a loose tubular structure to a densely consolidated monolithic structure through controlled consolidation processes, maintaining fiber orientation while achieving the required frame shape and mechanical strength
3Adaptability or versatility
If the frame is manufactured with varying thickness sections to accommodate different functional zones, then functional requirements are met, but maintaining constant thickness becomes difficult and manufacturing complexity increases
Solution Approach 1:
The invention applies different thickness characteristics to different zones of the frame (sealing zone, fixing zone, aerodynamic zone) by locally adjusting the tubular preform dimensions and consolidation parameters, achieving functional requirements while maintaining overall thickness control through a single continuous manufacturing process
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 method simplifies the manufacturing process, ensures a quasi-constant thickness, enhances mechanical characteristics, and improves sealing by maintaining fiber orientation, reducing the complexity and cost of producing aircraft window frames with improved strength and rigidity.
Implementation Method 1
solidified by spraying or injecting resin, then application of particular conditions of temperature and pressure allowing the polymerization of said resin
Data Source
Figure 1A~2B
Figure 3A~4A
Figure 4B~5B
AI summary
A method for manufacturing a ring-shaped frame made from composite material comprising the following steps: - slipping at least one tubular casing of dry fibres (9) over an assembly comprising at least two coaxial sub-assemblies (81, 82) that are axially movable relative to one another and between which a peripheral groove (11) is defined, disposed in the general plane of said frame; - forcing a portion of the tubular casing (9) into said groove (11) provided between the two sub-assemblies (81, 82) and tightening said two sub-assemblies (81, 82) so as to hold said portion (90) of the tubular casing (9) in said groove (11); - coupling the two parts (91, 92) of the casing (9) that are outside the groove (11), and folding the obtained coupling (93) onto one of the two sub-assemblies (81, 82) in order to obtain a preform (15) of dry fibres; - solidifying said preform (15) by polymerisation.