Composite Aircraft Window Frame Manufacturing via Hydrostatic Resin Injection
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Solution Overview
Problem
The manufacturing of composite aircraft window frames using existing methods, such as Resin Transfer Molding, faces challenges including complex fiber orientation, lengthy pre-compression processes, and potential defects leading to increased waste and costs due to galvanic coupling with metallic components.
Innovation Solution
A tool comprising a mold with a preform positioning system that maintains fiber orientation and uses hydrostatic pressure to impregnate a pre-impregnated material with thermosetting resin, ensuring consistent fiber direction and reducing post-forming time, while eliminating the need for pre-compression and minimizing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Resin Transfer Molding is used to manufacture composite aircraft window frames, then the frames have low defects and high repeatability of physical-mechanical performances, but the fiber orientation becomes complex and post-forming process time increases significantly
Solution Approach 1:
The invention applies preliminary compression to the preform before resin injection to pre-establish the desired fiber orientation and density distribution. This preliminary action prevents complex fiber orientation issues during resin infusion, eliminating the need for lengthy post-forming processes while maintaining high product quality
2Ease of manufacture
If a dry preform is used in Resin Transfer Molding, then the manufacturing process can proceed, but pre-compression step is always necessary and thickness reduction leads to formation of defects
Solution Approach 1:
The invention changes the physical state of the preform from dry to pre-impregnated (pre-coated with resin) before molding. This parameter change eliminates thickness reduction and defect formation during curing, while the use of flexible molds compensates for any volume changes and maintains manufacturing ease
3Strength
If metallic window frames are used in composite aircraft structures, then the frames provide structural strength, but galvanic coupling causes corrosion risks and increased inspection levels
Solution Approach 1:
The invention replaces heterogeneous metallic window frames with homogeneous composite window frames made from the same composite materials as the aircraft fuselage. This eliminates galvanic coupling between dissimilar metals and composites, removing corrosion risks and reducing inspection requirements while maintaining structural strength
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
The method and tool enable the production of composite aircraft window frames with reliable fiber orientation, low surface porosity, and high aesthetic finish, reducing production costs and waste, and eliminating the need for additional processing steps.
Implementation Method 1
uses hydrostatic pressure to impregnate a pre-impregnated material with thermosetting resin
Data Source
AI summary
The invention relates to a method for manufacturing a composite aircraft window frame; the method comprises the steps of: a) positioning in a mold a preform made of pre-impregnated material including dispersed fibers, with a predefined orientation, in a thermosetting resin matrix; b) closing the mold so as to define a gap between at least one surface of said preform and a portion of said mold; c) injecting thermosetting resin into the closed mold through an inlet opening of the mold itself, so as to fill the gap and completely lap said surface of the preform; and d) applying a uniform hydrostatic pressure on the surface by the injection of the resin.