Fuselage Reinforcement Element Using Pre-impregnated Composite

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Solution Overview

Problem

The aerospace, naval, and railway industries seek to enhance the mechanical properties and reduce the weight of fuselage structural elements while simplifying manufacturing processes, as traditional materials like metals fail to achieve optimal resistance and weight reduction.

Innovation Solution

A structural reinforcement element for fuselages is developed using pre-impregnated composite materials and resin-impregnated fibre reinforcement elements, where an external and internal reinforcement are embedded within a pre-impregnated composite material, eliminating the need for mechanical or adhesive joining through a process of overmoulding with filament winding and compression moulding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional metallic materials are used for fuselage structural elements, then mechanical strength and structural integrity are achieved, but weight reduction and optimal resistance are not attained

Engineering Contradiction:

Improvemechanical strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent applies composite materials consisting of a pre-impregnated composite material matrix with embedded resin-impregnated fibre reinforcement elements. This composite structure provides superior strength-to-weight ratio compared to traditional metallic materials, achieving both mechanical strength and weight reduction simultaneously. The combination of different material phases (composite matrix + fibre reinforcement) creates a hybrid structure that optimizes both properties.

Inventive Principle:

Principle #40Composite materials

2Strength

If multiple separate reinforcement elements are used, then structural integrity is improved, but manufacturing complexity and assembly time increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple reinforcement functions into a single integrated element. The pre-impregnated composite material and resin-impregnated fibre reinforcement elements are combined during the moulding process to form one unified structural component. This eliminates the need for separate assembly operations and reduces manufacturing complexity while maintaining structural integrity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reinforcement elements are prepared in advance with resin impregnation before being embedded in the pre-impregnated composite material. This preliminary preparation ensures proper material distribution and bonding characteristics are achieved before final assembly, simplifying the overall manufacturing process and ensuring consistent structural properties.

Inventive Principle:

Principle #10Preliminary action

3Strength

If mechanical or adhesive joining methods are used to attach reinforcement elements, then structural connection is achieved, but manufacturing time and production costs increase

Engineering Contradiction:

Improvestructural connectionVSAvoidmanufacturing time

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

The patent combines the reinforcement elements and the composite material into a single integrated component through co-moulding. The resin-impregnated fibre reinforcement elements are embedded within the pre-impregnated composite material during the same manufacturing cycle, eliminating the need for separate mechanical or adhesive joining operations. This significantly reduces manufacturing time and production costs.

Inventive Principle:

Principle #5Merging (Combining)

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 results in a lightweight, high-strength fuselage component with improved resistance to fatigue and corrosion, reduced weight, and simplified manufacturing, achieving enhanced structural integrity and cost-effectiveness.

Implementation Method 1

manufactured from pre-impregnated composite material, for example SMC or BMC, reinforced by means of two reinforcement elements manufactured from fibre, which may be carbon fibre, impregnated with resin

Methodology Applied

Scientific EffectResin impregnation: Absorption (physical)

Implementation Method 2

The object of the invention is therefore an internal structural reinforcement element for fuselages... manufactured from pre-impregnated composite material... reinforced by means of two reinforcement elements manufactured from fibre, which may be carbon fibre, impregnated with resin

Methodology Applied

Scientific EffectCompression moulding: Compression

Data Source

PatentUS12006019B2Structural internal reinforcement element for a fuselage, and procedure for the manufacture of said structural element

Publication Date: 2024.06.11 MUELLES Y BALLESTAS HISPANO ALEMANAS PROJECTS SL

AI summary

An internal structural reinforcement element for fuselages, where the internal structural reinforcement element has a longitudinal direction adapted for its placement in the longitudinal direction of the fuselage and a transversal direction perpendicular to the longitudinal direction, comprising:an external reinforcement element,an internal reinforcement element, located internally to the external reinforcement element in the transversal direction of the structural element,where both reinforcement elements are manufactured from resin-impregnated fibre, andan intermediate element, located between the external reinforcement element and the internal reinforcement element in the transversal direction of the structural element, the intermediate element being manufactured from pre-impregnated composite material.