Aircraft Fuselage Aperture Frame Manufacturing via Single-Mold Braiding
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Solution Overview
Problem
Current methods for manufacturing aperture surrounding frames for aircraft fuselages are time-consuming and costly, particularly when using composite materials, as they require complex pre-form demoulding and multiple pieces that increase assembly time and cost.
Innovation Solution
A method involving tubular braiding material cut into annular-shaped slices, layered around an inner mold, hot-formed, and cured to create a continuous, unitary aperture surrounding frame, using a single mold for both forming and injection to avoid pre-form demoulding and simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional composite frame manufacturing methods are used (multiple preforms, crossbeams, titanium plates), then the frame can be assembled to reinforce the fuselage, but the manufacturing time and assembly time increase significantly
Solution Approach 1:
The patent merges multiple separate frame components (crossbeams, frames, joining elements, titanium plates) into a single integrated aperture surrounding frame manufactured as one continuous preform. This eliminates the need for multiple manufacturing processes and assembly operations, directly reducing both manufacturing time and assembly time while maintaining the required reinforcement strength through the integrated structure.
Solution Approach 2:
The patent segments the frame manufacturing process into a single continuous preform creation step followed by direct installation, eliminating the traditional multi-step process of manufacturing separate components and then assembling them. This segmentation of the overall process into fewer steps reduces cumulative manufacturing and assembly time.
2Strength
If multiple separate frame components are used (composite frames, metallic beams, joining elements), then the frame can be assembled to the fuselage, but the assembly complexity and number of ancillary pieces increase
Solution Approach 1:
The patent combines multiple separate frame components into a single integrated aperture surrounding frame that is manufactured as one continuous preform. This merging eliminates the need for multiple joining elements, ancillary pieces, and complex assembly procedures, directly reducing assembly complexity while preserving the required structural strength through the integrated design.
3Manufacturing precision
If separate molds are used for forming and injection, then the preform can be manufactured, but the demoulding process becomes complex and time-consuming
Solution Approach 1:
The patent employs a single mold that serves dual functions: first as the forming mold to create the preform with precise shape, and then as the injection mold for resin impregnation. This multi-functional mold eliminates the need for separate demoulding operations between forming and injection, directly reducing demoulding time and process complexity while maintaining manufacturing precision through the same mold's consistent geometry.
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 significantly reduces manufacturing time and cost while ensuring consistent strength and adaptability, providing a versatile solution for both window and door frames with improved fiber orientation and reduced complexity.
Implementation Method 1
the at least one braiding slice around the inner mold is hot-formed to obtain an aperture surrounding frame pre-form
Implementation Method 2
the aperture surrounding frame pre-form is cured to obtain a cured composite aperture surrounding frame
Data Source
Figure 1~2
Figure 3~4
Figure 5a~6a
AI summary
The present invention refers to a forming tool for manufacturing an aperture surrounding frame (1) for an aircraft fuselage, the forming tool comprising: • an inner mold (4) having an annular shape, and comprising an outer surface (5) with a central section (9) positioned between an upper (10) and a lower section (11), the central section (9) protruding from the upper (10) and the lower section (11), • a membrane (8), and a lower (6) and an upper top (7), wherein both tops (6, 7) have a diameter larger than the diameter of the inner mold (4).