Monolithic Composite Vehicle Frames Merging Components
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Solution Overview
Problem
Current vehicle support systems, particularly in aircraft, are complex and time-consuming to manufacture and assemble, requiring numerous components and processes such as welding and fastening, which increases production time and maintenance efforts.
Innovation Solution
The implementation of monolithic composite structures with planar and non-planar regions, configured to support loads and dissipate energy, reduces the complexity by forming frames as single components through a single cure process, eliminating the need for secondary bonding and re-curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple separate components (beams, ribs, truss structures) are used to form the support system, then the structural support capability is improved, but the manufacturing complexity and assembly time increase significantly
Solution Approach 1:
The patent combines multiple separate structural components (beams, ribs, truss structures) into a single monolithic composite frame structure. This integration maintains the structural support capability while eliminating the need for multiple discrete parts, fasteners, and weld joints, thereby reducing manufacturing complexity and assembly operations.
Solution Approach 2:
The monolithic composite frame structure performs multiple functions simultaneously: it provides structural support, connects to the fuselage skin, supports flooring, and integrates curvature to match the fuselage contour. This multi-functionality replaces what previously required multiple specialized components.
2Reliability
If multiple separate components are connected through fasteners and weld joints, then the structural integrity is improved, but the assembly time and production cost increase
Solution Approach 1:
By merging multiple components into a single monolithic structure during manufacturing, the patent eliminates post-manufacturing assembly operations including drilling holes, installing fasteners, and performing weld joints. The structural integrity is maintained through the continuous composite material structure while assembly time is dramatically reduced.
3Strength
If traditional metal or composite components are used with multiple connection methods, then the load support capability is improved, but the maintenance requirements and inspection needs increase
Solution Approach 1:
The monolithic composite frame structure eliminates multiple connection points (fasteners, weld joints) that would require inspection and potential repair. The single integrated structure has fewer potential failure points and requires less maintenance while maintaining load support capability through its continuous composite construction.
4Manufacturing precision
If multiple manufacturing operations (positioning, drilling, fastening, welding) are performed, then the structural precision is improved, but the production time and cost increase
Solution Approach 1:
The monolithic composite frame structure is manufactured with precise geometries and integrated features (including curvature and connection interfaces) during the initial molding process. This preliminary formation of all structural features eliminates subsequent precision operations like drilling and fastening, maintaining manufacturing precision while reducing production time.
Data Source
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AI summary
MONOLITHIC COMPOSITE STRUCTURES FOR VEHICLES A method and apparatus comprising a monolithic composite structure (402), a first edge (408) of the monolithic composite structure, and a second edge (410) of the monolithic composite structure. The first edge of the monolithic composite structure has a first shape (422) configured to be connected to a structure in a vehicle. The second edge of the monolithic composite structure has a second shape (424) configured to be connected to a body of the vehicle.