Integral Aircraft Door Frame With Cross-Strut Force Distribution
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Solution Overview
Problem
Conventional aircraft door designs are heavy and complex, requiring multiple parts and a time-consuming production process, and fail to efficiently transfer forces from the fuselage into the door structure.
Innovation Solution
A door frame unit with an inner and outer frame, connected by cross struts, that distributes forces efficiently and reduces the number of components, allowing for a more integrated and lightweight construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional door frame designs with multiple individual parts are used, then structural strength and force absorption are improved, but device complexity and manufacturing time increase
Solution Approach 1:
The patent combines multiple individual door frame parts (frame, lintel, intercostal, sill, doublers) into a single integrated door frame unit. This merging maintains the force absorption capability through the unified structure while eliminating the complexity of assembling multiple separate components, directly resolving the contradiction between strength and device complexity.
Solution Approach 2:
The integrated door frame unit is designed with distinct functional zones (inner frame for door mounting, outer frame for force distribution, cross struts for reinforcement) that can be manufactured as one piece. This segmentation of functions within a unified structure allows the unit to handle complex force patterns while simplifying manufacturing compared to traditional multi-part designs.
2Strength
If conventional door frame designs with multiple individual parts are used, then structural strength is improved, but manufacturing time and production efficiency worsen
Solution Approach 1:
By merging multiple door frame components into a single integrated unit, the manufacturing process is simplified from assembling multiple parts to producing one piece. This maintains structural strength while significantly improving productivity and reducing manufacturing time, as the integrated unit can be manufactured in a single operation rather than requiring multiple assembly steps.
3Strength
If conventional door frame designs are used, then force distribution is achieved, but weight increases
Solution Approach 1:
The integrated door frame unit consolidates the functions of multiple heavy individual parts into a single optimized structure. This merging maintains the force distribution capability while reducing overall weight, as the unified design eliminates redundant materials and reduces the total amount of structural material needed compared to traditional multi-part constructions.
4Area of stationary object
If the outer frame runs at an angle to the cross struts, then force distribution over larger area is improved, but manufacturing precision requirements increase
Solution Approach 1:
The outer frame is designed to run at an angle to the cross struts specifically in areas directly neighboring corners of the inner door frame, while maintaining parallel alignment in other regions. This localized angular configuration optimizes force distribution at critical corner areas without imposing high precision requirements across the entire structure, resolving the contradiction between force distribution area and manufacturing precision.
Data Source
AI summary
A door frame unit for integration into a fuselage of an air vehicle includes at least one door frame component, wherein the door frame unit includes an inner frame and an outer frame surrounding the inner frame, wherein the inner frame defines a door frame opening with horizontal edges and vertical edges, in which a door is mountable, wherein a plurality of cross struts extend between the inner frame and the outer frame and are rigidly connected to the inner frame and the outer frame, and wherein the outer frame runs at an angle to the cross struts at least at areas directly neighboring corners of the inner door frame.