Integral Aircraft Frame Member Design
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Solution Overview
Problem
The complex construction of aircraft frames, composed of multiple individual elements glued, riveted, or screwed together, leads to time-consuming and inefficient manufacturing, lack of flexibility, and safety concerns due to fixed dimensions and the inability to accommodate varying stress areas or system lines effectively.
Innovation Solution
A one-piece frame member with integral clip, shear web, and frame regions formed from an extrusion molded profile, utilizing a milling process for precise and automated manufacturing, allowing for varying dimensions and thicknesses, and incorporating cutouts with border reinforcement for system line accommodation, reducing weight and enhancing safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple individual elements are used to construct the frame, then the frame can be assembled from standardized parts, but the manufacturing becomes time-consuming and complex
Solution Approach 1:
The patent merges multiple separate frame components (frame elements, clips, shear webs, reinforcement straps, and angles) into a single integrated frame member. This consolidation eliminates the need for multiple connection elements and complex assembly procedures, directly resolving the contradiction by providing both structural flexibility and simplified construction.
Solution Approach 2:
The integrated frame member serves multiple functions simultaneously: it provides structural support, incorporates connection features for skin and stringers, includes reinforcement areas for high-stress zones, and offers mounting points for system lines. This multi-functionality resolves the contradiction by eliminating the need for separate standardized parts while maintaining adaptability.
2Ease of manufacture
If multiple connection elements are used to join frame parts, then the frame can be assembled, but the weight increases
Solution Approach 1:
By combining the frame structure and connection elements into a single integrated member, the patent eliminates the weight of separate clips, shear webs, reinforcement straps, and angles along with their connection fasteners. The integrated design maintains all necessary connection functions while significantly reducing overall frame weight.
3Productivity
If fixed thickness and dimensions are used for the frame, then manufacturing is simplified, but flexibility for stress areas is lost
Solution Approach 1:
The integrated frame member incorporates varying thicknesses and cross-sectional dimensions at different locations to match local stress requirements. High-stress areas feature reinforced sections with increased thickness, while low-stress areas maintain thinner profiles. This local variation resolves the contradiction by providing both manufacturing efficiency through a single-piece construction and adaptability for stress distribution.
4Adaptability or versatility
If flanging holes are made into the frame, then system lines can be integrated, but cracks may occur
Solution Approach 1:
The patent integrates system line accommodation features directly into the molded frame structure, eliminating the need for separate flanging holes that would compromise structural integrity. The design incorporates channels, recesses, or integrated mounting points for electrical cables and pipes within the frame's geometry, resolving the contradiction by providing system line accommodation without creating stress concentration points that lead to cracking.
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 simplifies assembly, reduces weight, enhances design flexibility, improves safety by protecting system lines, and increases durability by eliminating the need for multiple connections and allowing for tailored stress distribution, resulting in a more efficient and cost-effective manufacturing process.
Implementation Method 1
the frame member is formed from one extrusion molded profile
Implementation Method 2
the frame member is formed from the one extrusion molded profile by a milling process
Data Source
AI summary
According to an exemplary embodiment of the present invention, a frame member for an aircraft is provided comprising a clip region and a frame region. According to an aspect of this exemplary embodiment of the present invention, the clip region, shear web region and the frame region are integrated into the frame member and be formed from an extrusion mold by a milling process. Advantageously, this allows for a reduced number of individual elements for forming a frame member and provides the flexibility of variation of the forms and dimensions of a frame member for an aircraft.