Composite Tubular Member Vertical Curing and Frame Fabrication

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Solution Overview

Problem

Tubular structures, such as aircraft fuselages, face challenges with sagging or slumping due to insufficient internal strength during manufacturing, requiring additional bracing and increased manufacturing time as the frame is fabricated in series with the tubular member.

Innovation Solution

A method involving a vertically-oriented tubular mandrel where a composite material is deposited and cured with an inner expandable mandrel to provide structural integrity early on, allowing for parallel fabrication of a geodesic frame composed of oppositely-wound spirals, reducing the need for bracing and shortening manufacturing time.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the tubular member is placed horizontally during manufacturing, then the frame can be fabricated in series with the tubular member, but the tubular member sags or slumps due to insufficient internal strength

Engineering Contradiction:

Improvemanufacturing processVSAvoidinternal strength of tubular member

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent applies preliminary action by placing the tubular member in a vertical orientation during the early stages of manufacturing, before the frame is installed. This vertical positioning prevents sagging and slumping by utilizing gravity to maintain the tubular member's shape, eliminating the need for additional bracing and fixtures that would otherwise be required to support the member's weight during horizontal fabrication.

Inventive Principle:

Principle #10Preliminary action

2Device complexity

If the frame is fabricated in series with the tubular member, then the manufacturing process is simplified, but the overall manufacturing time increases

Engineering Contradiction:

Improvemanufacturing process complexityVSAvoidmanufacturing time

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The patent enables parallel fabrication by performing preliminary actions - specifically, installing the frame while the tubular member is in vertical orientation during the layup process. This allows the frame and tubular member to be manufactured simultaneously rather than sequentially, reducing overall manufacturing time without requiring complex additional equipment or processes.

Inventive Principle:

Principle #10Preliminary action

3Shape

If additional bracing and fixtures are used to retain the shape of the tubular structure, then sagging is prevented, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improveshape retention of tubular memberVSAvoidbracing and fixtures

Core Design Contradiction:

ShapeVSDevice complexity

Solution Approach 1:

The patent eliminates the need for additional bracing and fixtures by using preliminary action - placing the tubular member in a vertical orientation during manufacturing. This orientation naturally prevents sagging and shape distortion through gravity, simplifying the support system to just the vertical positioning mechanism and removing the need for complex bracing structures, fixtures, and associated installation/removal procedures.

Inventive Principle:

Principle #10Preliminary 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 approach enhances the structural integrity of tubular members early in the manufacturing process, reduces the use of bracing and fixtures, and decreases overall manufacturing time by enabling parallel fabrication of the frame, resulting in a more efficient and cost-effective production method.

Implementation Method 1

expanding the inner expandable mandrel so as to cause the inner expandable mandrel to press the composite tubular member against the inner surface of the tubular mandrel

Methodology Applied

Scientific EffectExpansion:

Implementation Method 2

depositing a composite material on an inner surface of the tubular mandrel as the tubular mandrel is rotated so as to form a composite tubular member on the inner surface of the tubular mandrel

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Implementation Method 3

curing the composite tubular member while being sandwiched between the inner expandable mandrel and the tubular mandrel

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS11634206B2Tubular structure and a method of manufacturing thereof

Publication Date: 2023.04.25 THE BOEING CO

AI summary

Methods and structures are disclosed. An example method includes: rotating a tubular mandrel about a longitudinal axis of the tubular mandrel; depositing a composite material on an inner surface of the tubular mandrel to form a composite tubular member on the inner surface of the tubular mandrel; inserting and expanding an inner expandable mandrel within the composite tubular member to cause the inner expandable mandrel to press the composite tubular member against the inner surface of the tubular mandrel; curing the composite tubular member; removing the inner expandable mandrel; placing a frame within the composite tubular member; and removing the tubular mandrel so as to obtain the composite tubular member with the frame placed therein.