Monolithic Composite Fuselage Reducing Joint Weight
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Solution Overview
Problem
Aircraft components made from fiber-reinforced composites, such as carbon fiber-reinforced plastics, often require multiple joints for assembly, leading to increased weight and reduced flight efficiency due to the mass accumulation of adhesives and fasteners, which compromises the structural integrity and aerodynamics.
Innovation Solution
Producing aircraft bodies with monolithic upper and lower shells made of carbon fiber-reinforced plastics, where the empennage is integrated into either shell, reducing the number of joints and allowing for a hollow body design that minimizes weight while maintaining high strength and rigidity, using a prepreg manufacturing process with autoclave curing for uniform shaping and bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple joints are used for assembly of aircraft components, then structural integrity can be maintained, but weight increases and flight efficiency decreases
Solution Approach 1:
The patent merges multiple separate aircraft components into a single monolithic structure made of fiber-reinforced composite material. The fuselage, wings, and empennage are integrated as one piece, eliminating the need for multiple joints, adhesives, and fasteners that would otherwise be required to assemble separate components, thereby reducing weight while maintaining structural integrity.
Solution Approach 2:
The patent uses fiber-reinforced composite materials (such as carbon fiber-reinforced plastics) to create a monolithic structure that combines high strength and rigidity with low weight. The composite material allows for a single-piece construction that would be impossible to achieve with traditional metals or simple materials, resolving the contradiction between strength and weight.
2Ease of manufacture
If multiple joints and fasteners are used for assembly, then components can be connected, but mass accumulation of adhesives and fasteners reduces flight efficiency
Solution Approach 1:
By merging all components into a single monolithic structure, the patent eliminates the need for adhesives, fasteners, and multiple assembly steps. The entire aircraft body is manufactured as one piece, removing the mass accumulation of joining materials that would otherwise reduce flight efficiency.
3Ease of manufacture
If conventional manufacturing processes are used, then components can be produced, but the outer surface shape cannot be optimized for aerodynamics
Solution Approach 1:
The use of fiber-reinforced composite materials enables complex aerodynamic shapes to be molded directly into the monolithic structure during manufacturing. The composite material's flexibility allows for optimization of the outer surface shape for aerodynamic performance while maintaining manufacturability through modern composite fabrication techniques.
4Ease of operation
If joints are used to connect empennage components, then assembly is enabled, but the number of joints increases total weight
Solution Approach 1:
The patent merges the empennage components with the main fuselage structure into a single monolithic piece, eliminating the need for separate joints and fasteners. This integration removes the weight associated with multiple joint areas while maintaining full assembly capability through the unified structure.
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 significantly lighter and more stable aircraft body with reduced weight and increased flight efficiency by eliminating unnecessary joints and distributing structural reinforcement evenly, while accommodating essential equipment within the hollow body.
Implementation Method 1
To cure these prepreg components, so-called autoclaves are used in which the prepreg components are treated under overpressure of up to 10 bar for several hours at temperatures of 120° C. to 200°° C., whereby complete curing of the evacuated prepreg components can be achieved.
Data Source
AI summary
A main aircraft body is made of fiber-reinforced composite material. The main aircraft body includes a load-bearing structure configured in the form of an elongate fuselage. Two wings are arranged laterally on the elongate fuselage. The wings are configured such that a lifting force is generated for the aircraft. A plurality of receiving devices for receiving drive means are formed on the wings. The main aircraft body is formed from an upper shell and a lower shell. The upper shell and the lower shell are connected to one another along a common connecting surface. An empennage is arranged at a tail of the fuselage. The empennage is formed by a pair of empennage surfaces. Guide surfaces of the pair of empennage surfaces are oriented in a V-shaped manner in relation to one another in a horizontal direction of flight. The upper shell is produced in one piece.