Integral Composite Fuselage Skin Eliminating Stringers
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Solution Overview
Problem
Traditional aircraft fuselage sections with stringers and ribs project into the interior volume, reducing cabin space and requiring significant installation space for stiffening elements.
Innovation Solution
A method using a construction mold with resin-impregnated fibers applied in different orientations to form a fuselage section with an integral stiffening structure between inner and outer layers, eliminating projections into the interior and enhancing structural stability without reducing interior space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional stringers and ribs are used for stiffening the fuselage section, then structural stability is improved, but the usable cabin diameter is reduced due to the installation space required for these elements
Solution Approach 1:
The patent merges the outer skin and stiffening elements into a single integrated composite structure. The fiber reinforcement elements are directly embedded within the skin material itself, eliminating the need for separate attached stringers and ribs. This integration maintains structural stability while maximizing the usable cabin diameter by removing protruding stiffening elements.
Solution Approach 2:
The patent employs composite materials consisting of a matrix material (such as polymer or metal) reinforced with fiber reinforcement elements (such as carbon fiber, glass fiber, or aramid fiber). This composite structure provides high structural stability and stiffness-to-weight ratio, allowing the skin itself to serve as the stiffening structure without requiring additional protruding elements, thereby preserving cabin space.
2Stability of the object's composition
If the outer skin thickness is increased to achieve required structural stiffness, then structural stability is improved, but weight increases
Solution Approach 1:
The patent uses composite materials with high stiffness-to-weight ratio, where fiber reinforcement elements (carbon fiber, glass fiber, aramid fiber) are embedded in a matrix material. These composites provide the required structural stiffness with significantly reduced thickness and weight compared to traditional metal skins, directly addressing the contradiction between structural stiffness and weight.
Solution Approach 2:
The patent implements variable fiber orientation and density within different regions of the skin to optimize structural performance locally. Fiber reinforcement elements are arranged with specific orientations (e.g., 0°, 45°, 90°) in different zones to match the stress distribution patterns, providing maximum stiffness where needed while minimizing material usage and weight in less critical areas.
3Stability of the object's composition
If fiber reinforcement elements are applied in high density to increase structural stability, then structural stability is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses pre impregnated fiber materials (prepregs) where fibers are already saturated with resin before application. This preliminary impregnation simplifies the manufacturing process by eliminating the need for separate resin application and distribution steps, allowing direct placement of fibers in the mold with controlled orientation and density, thereby reducing manufacturing complexity while maintaining high structural stability.
Solution Approach 2:
The patent employs a universal manufacturing process using mold tools that can accommodate different fiber orientations, densities, and configurations through standardized tooling and curing procedures. The same basic molding and curing infrastructure can produce skins with varying fiber reinforcement patterns, reducing the need for specialized equipment for each design variation and simplifying overall manufacturing complexity.
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
The method allows for increased cabin space, reduced weight, and improved structural stiffness, enabling higher altitudes and lower fuel consumption while minimizing air resistance and environmental impact.
Implementation Method 1
all of the fibers applied to the construction mold are joined to one another by means of a curing process
Data Source
AI summary
In accordance with the method, an inside layer of a fuselage section skin made from first fibers is placed on a manufacturing surface, the first fibers being placed in one or more first fiber directions. On the inside layer, a stiffening structure is formed from stiffening fibers, the stiffening fibers being placed in one or more stiffening fiber directions. An outside layer of the fuselage section skin, comprising fourth fibers, is placed on the stiffening structure formed from stiffening fibers, the fourth fibers being placed in one or more fourth fiber directions. The stiffening structure is designed and developed in such a way that the fuselage section does not require an additional stiffening structure, is connected with the fuselage section skin, and comprises the inside layer, the stiffening structure, and the outside layer; in particular, an additional stiffening structure in the form of stringers and frames is not required.