Continuous Fiber Reinforcement for Airship Hulls
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Solution Overview
Problem
Existing airship and aerostat construction methods rely on structural joints that are weak, large, and difficult to construct, limiting the strength and weight of gas-filled hulls due to the use of weak adhesives and resins, and the process of cutting and assembling gore pieces degrades the material's structural integrity and increases construction time.
Innovation Solution
The use of continuous fiber reinforcement applied in a helical pattern around the circumference of a gas-filled membrane, eliminating the need for structural joints by affixing and coating the fibers to the outer surface, which can be done using self-propelled fiber placement devices or rotating the membrane for efficient application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If structural joints are used to assemble airship hulls from flat materials, then the hull can be constructed into a three-dimensional gas-tight volume, but the overall strength is limited by the weak adhesives and resins in the joints, resulting in large, heavy, and difficult-to-construct joints
Solution Approach 1:
The patent removes structural joints entirely from the airship hull construction by applying continuous fibers directly to the inflated membrane surface. The fibers are deposited in a helical pattern that wraps around the circumference multiple times, creating a jointless reinforcement system that eliminates the need for adhesives and resins at joints.
Solution Approach 2:
The patent uses composite materials consisting of continuous fibers (such as carbon fiber, glass fiber, or aramid) applied over the membrane surface. This composite structure provides both strength and lightweight properties, replacing the traditional jointed assembly approach with a unified fiber-reinforced shell.
2Stability of the object's composition
If flat materials are cut and assembled into three-dimensional shapes using structural joints, then the hull can be formed, but the material's structural integrity is degraded and construction time increases
Solution Approach 1:
The patent applies continuous fibers in an unbroken sequence around the airship hull circumference, with each fiber wrapping multiple times without interruption. This continuous application method preserves the material's structural integrity by avoiding cuts and assemblies, and significantly reduces construction time compared to traditional piece-by-piece assembly.
Solution Approach 2:
The membrane is inflated to its final three-dimensional shape before the fiber application process begins. This preliminary inflation allows the continuous fibers to be deposited directly onto the pre-formed surface, eliminating the need to cut and assemble flat materials into shape, thereby preserving structural integrity and reducing construction time.
3Ease of manufacture
If traditional bonded structural joints are used, then flat materials can be transformed into three-dimensional volumes, but the joints are large, heavy, and difficult to construct
Solution Approach 1:
The patent replaces the mechanical bonding system (adhesives and resins in structural joints) with a direct fiber-to-membrane attachment system. Continuous fibers are applied and bonded directly to the membrane surface in a helical pattern, eliminating the need for separate joint components and making the construction process simpler and lighter.
Solution Approach 2:
The patent changes the construction approach from assembling discrete jointed components to applying continuous fibers in a helical pattern with specific wrap angles. This parameter change (from jointed assembly to continuous fiber deposition) simplifies manufacturing and reduces weight by eliminating joint hardware and excess adhesive materials.
Data Source
AI summary
An airship hull is disclosed. The airship hull comprises a gas-tight shape fabricated from a membrane. The airship hull comprises one or more fibers applied to an outer surface of the gas-tight shape in a continuous manner such that a particular one of the one or more fibers wraps around a circumference of the gas-tight shape multiple times, wherein the applied one or more fibers are affixed to the outer surface of the gas-tight shape.