Modular Fuselage Flange Assembly for Hydrogen Tank Integration

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Solution Overview

Problem

Existing aircraft designs with hinged doors for hydrogen tanks are heavy and not designed for continuous load transfer, limiting their use in hydrogen-powered aircraft and increasing weight and costs.

Innovation Solution

A fuselage structure with interconnected fuselage sections using circumferential flanges and fasteners, allowing for easy assembly and disassembly of hydrogen tanks, enabling continuous load transfer and efficient space utilization.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If hinged doors with latching mechanisms are used for tank installation, then ease of operation is improved, but weight increases and continuous load transfer capability deteriorates

Engineering Contradiction:

Improveease of tank installationVSAvoidweight of door mechanism

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The fuselage is divided into modular sections with circumferential flanges at each end, allowing independent assembly and disassembly of tank structures. This segmentation eliminates the need for heavy hinged doors while maintaining ease of operation through standardized connection interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The circumferential flanges are integrated directly into the fuselage structure itself, combining the structural load-bearing function with the assembly interface function. This eliminates separate door mechanisms while providing both structural integrity and ease of tank installation.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of operation

If hinged doors are used for tank access, then ease of operation is improved, but device complexity increases

Engineering Contradiction:

Improveease of tank accessVSAvoidcomplexity of door mechanism

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The fuselage structure is segmented into modular sections with standardized circumferential flanges, replacing complex hinged door mechanisms with simple bolted connections. This reduces device complexity while maintaining ease of tank access through modular assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using a door that opens into the fuselage interior, the design inverts the approach by providing open access through circumferential flanges that allow direct insertion and removal of tank structures from the exterior, eliminating the door mechanism entirely.

Inventive Principle:

Principle #13The other way round (Inversion)

3Volume of moving object

If tanks are installed inside the fuselage, then space utilization is improved, but manufacturing time increases

Engineering Contradiction:

Improvespace utilizationVSAvoidmanufacturing speed

Core Design Contradiction:

Volume of moving objectVSProductivity

Solution Approach 1:

Circumferential flanges are pre-installed on fuselage sections during primary manufacturing, and tank structures are pre-assembled with matching flanges. This preliminary preparation enables rapid final assembly without time-consuming on-site modifications, improving both space utilization and manufacturing efficiency.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The fuselage is divided into sections with integrated circumferential flanges, allowing parallel assembly of multiple sections and tanks before final integration. This modular approach increases space utilization while reducing total manufacturing time through concurrent fabrication processes.

Inventive Principle:

Principle #1Segmentation

4Strength

If circumferential flanges with fasteners are used, then strength is improved, but device complexity increases

Engineering Contradiction:

Improveload transfer capabilityVSAvoidcomplexity of connection structure

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The circumferential flanges serve multiple functions simultaneously: they provide structural load transfer paths, serve as assembly interfaces for tanks, and act as connection points for fuselage sections. This multi-functionality increases strength while avoiding additional complex components.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

Standardized circumferential flanges with uniform fastener patterns are used throughout the fuselage structure, creating homogeneous connection details. This standardization simplifies manufacturing and assembly processes while maintaining consistent high strength across all connections.

Inventive Principle:

Principle #33Homogeneity

Data Source

PatentUS20260048829A1Fuselage structure of an aircraft, method for assembling a fuselage structure and aircraft comprising a fuselage structure

Publication Date: 2026.02.19 AIRBUS OPERATIONS GMBH

AI summary

A fuselage structure of an aircraft includes a first fuselage section and a second fuselage section connected to the first fuselage section, the second fuselage section including at least one first fuselage vessel extending the first fuselage section in a longitudinal direction, with the first fuselage section and the first fuselage vessels comprising circumferential flanges arranged at longitudinal ends of the first fuselage section and the first fuselage vessels extending radially in the first fuselage vessels and the first fuselage section wherein fasteners extend through abutting flanges of the first fuselage section and the fuselage vessel to establish a force-fit connection between the first fuselage section and the first fuselage vessels, when assembled, and wherein the first fuselage vessel provides a storage space for at least one tank structure. Also disclosed are a method for assembling the fuselage structure and an aircraft including the fuselage structure.