Composite Splice Joint with Tapered Regions for Fuselage Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for joining fuselage sections of aircraft are time-consuming and costly due to the use of expensive metallic materials like titanium, requiring significant drilling and deburring, and often necessitate the use of shims for alignment, which increases labor and material costs.
Innovation Solution
A splice joint design utilizing a composite material strap with tapered regions and fittings, which eliminates the need for metal components and shims, allowing for efficient assembly and reduced material costs by using a strap and fittings with tapered sections for alignment and attachment, formed through composite ply dropping without post-formation machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If titanium splice fittings are used to join fuselage sections, then the strength and reliability of the joint is improved, but the material cost and manufacturing cost increase significantly
Solution Approach 1:
The patent changes the material parameter from metallic titanium to composite materials (carbon fiber reinforced plastic), maintaining structural strength while significantly reducing material cost and weight. The composite strap with tapered regions provides equivalent load-bearing capability without the high cost associated with titanium fittings.
Solution Approach 2:
The invention uses composite materials (carbon fiber reinforced plastic) to replace metallic titanium in the splice fitting. The composite strap and fittings provide the necessary strength and stiffness for joining fuselage sections while reducing both material cost and weight compared to traditional metallic components.
2Reliability
If traditional drilling and deburring processes are used for metallic splice fittings, then the joint strength is ensured, but the assembly time and labor cost increase significantly
Solution Approach 1:
The patent changes the material parameter from metallic titanium to composite materials (carbon fiber reinforced plastic), maintaining structural strength while significantly reducing material cost and weight. The composite strap with tapered regions provides equivalent load-bearing capability without the high cost associated with titanium fittings.
Solution Approach 2:
The invention uses composite materials (carbon fiber reinforced plastic) to replace metallic titanium in the splice fitting. The composite strap and fittings provide the necessary strength and stiffness for joining fuselage sections while reducing both material cost and weight compared to traditional metallic components.
3Manufacturing precision
If shims are used to align fuselage sections and fit splice fittings, then the alignment precision is improved, but the assembly time and complexity increase
Solution Approach 1:
The patent applies local quality by creating tapered regions at specific locations on the composite strap where precision is needed. The tapered sections provide self-aligning features that concentrate alignment functionality in specific areas rather than requiring shims throughout the assembly, reducing overall complexity while maintaining precision where critical.
Solution Approach 2:
The tapered regions on the composite strap provide self-aligning capabilities that eliminate the need for external shims. The geometry of the tapered sections automatically guides proper positioning and alignment during assembly, making the system self-aligning without requiring additional alignment components or procedures.
Data Source
AI summary
The disclosed shell structure splice (10) and method includes a first panel (108) having a first edge, a second panel having a second edge, the second edge being positioned in edgewise alignment with the first edge to form a splice joint, a strap (12) bridging the splice joint and attached to the first panel and the second panel, the strap having a first tapered region (22a) and a second tapered region (22b), a first fitting (24a) having a tapered section (34)and a flat section (36), the tapered section being attached to the first tapered region of the strap, and a second fitting (24b) having a tapered section and a flat section, the tapered section being attached to the second tapered region of the strap.