Hybrid One-Piece Composite Door Core for Reduced Assembly

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Solution Overview

Problem

Existing aircraft door manufacturing methods, whether metal or composite, face challenges of high weight, complex assembly, lengthy production times, and stress concentration due to multiple parts and mechanical fasteners, which hinder mass production and maintenance efficiency.

Innovation Solution

A two-stage process involving fiber draping, assembly, curing, and machining of a one-piece composite core, followed by addition of structural elements, reduces assembly phases and fasteners, enabling adaptation to various needs and simplifying production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If multiple separate parts are assembled to create a robust door structure, then strength and reliability are improved, but device complexity and assembly time increase

Engineering Contradiction:

Improvedoor structure strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges multiple separate door components (panel, stiffeners, frames) into a single monoblock composite structure manufactured through resin transfer molding. This integration eliminates the need for mechanical fasteners and assembly operations, resolving the contradiction by maintaining structural strength while dramatically reducing assembly complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent uses composite materials (fiber reinforcement with resin matrix) to create the monoblock structure, providing both the necessary strength and structural integrity while enabling a single-piece manufacturing approach that eliminates complex assembly of multiple metal parts

Inventive Principle:

Principle #40Composite materials

2Manufacturing precision

If metal machining and forming techniques are used to ensure quality control, then manufacturing precision is improved, but weight increases

Engineering Contradiction:

Improvequality controlVSAvoiddoor weight

Core Design Contradiction:

Manufacturing precisionVSWeight of moving object

Solution Approach 1:

The patent replaces traditional metal materials with composite materials (fibers embedded in resin matrix), achieving both weight reduction and maintained manufacturing precision through controlled resin transfer molding processes that ensure consistent fiber distribution and curing

Inventive Principle:

Principle #40Composite materials

3Reliability

If conventional assembly methods with mechanical fasteners are used, then structural reliability is improved, but productivity decreases due to lengthy assembly and installation times

Engineering Contradiction:

Improvestructural reliabilityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent combines all structural components into a single monoblock manufactured through resin transfer molding, eliminating mechanical fasteners and assembly operations entirely. This integration maintains structural reliability through continuous material structure while dramatically improving productivity by removing time-consuming assembly steps

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If monoblock manufacturing process is used to reduce assembly phases, then productivity is improved, but device complexity increases due to specific tooling requirements

Engineering Contradiction:

Improvemanufacturing speedVSAvoidtooling complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent replaces complex mechanical assembly systems with a resin transfer molding process that uses fluid injection to impregnate fiber preforms. This substitution achieves monoblock manufacturing with improved productivity while the molding tooling, though specialized, is simpler than the complex mechanical fastening and assembly tooling required by conventional methods

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 enhances manufacturing efficiency, reduces weight, and improves structural adaptability while minimizing mechanical fasteners, facilitating quicker production and easier adaptation to different applications.

Implementation Method 1

fiber deposition and resin transfer molding process

Methodology Applied

Scientific EffectResin transfer molding:

Implementation Method 2

curing of the assembly and obtaining the one-piece core

Methodology Applied

Scientific EffectCuring:

Data Source

PatentUS20250229503A1Method for producing a hybrid one-piece composite structure and door produced by said method

Publication Date: 2025.07.17 LATECOERE

AI summary

Process for manufacturing a composite stiffened structure including a panel (3) and at least one stiffener (4). The manufacturing process includes the following steps to obtain a one-piece core (2): fiber draping of the elements of the panel (3) and the stiffeners (4); assembly of the elements of the stiffeners (4) on the panel (3); curing of the assembly and obtaining the monoblock core (2); machining of the monoblock core (2); manufacture of additional structural elements intended to stiffen the stiffened structure and to support installation parts; combination of the additional structural elements with the machined monoblock core (2).