Monolithic Planar Pressure Bulkhead for Aircraft Fuselage

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Solution Overview

Problem

Existing planar pressure bulkhead designs for air- and spacecrafts are complex, heavy, and require additional structural elements, limiting cabin space and increasing assembly complexity due to bending stresses and the need for rigid frames and tension elements.

Innovation Solution

A monolithic sandwich-like design for the planar pressure bulkhead featuring a first and second planar wall with circumferential monolithic reinforcing elements, eliminating the need for foam or honeycomb cores and allowing a continuous, lightweight connection to the fuselage structure, which simplifies assembly and reduces weight by using a simple L-bracket for load transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional planar pressure bulkhead designs with rigid frames, L-profiles, and tension elements are used, then structural strength and load distribution are improved, but device complexity and weight increase

Engineering Contradiction:

Improvestructural strengthVSAvoiddevice complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent merges the functions of multiple separate structural elements (rigid frames, L-profiles, tension elements, radial stiffeners) into a single integrated monolithic sandwich structure. The two planar walls and circumferential reinforcing elements form a unified load-bearing assembly that simultaneously provides strength, stiffness, and load distribution without requiring separate connection components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention extracts and eliminates unnecessary structural elements from conventional designs. By removing rigid frames, L-profiles, tension elements, and foam/honeycomb cores, the patent achieves a simplified structure that relies on the inherent strength of the monolithic sandwich construction with circumferential reinforcing elements.

Inventive Principle:

Principle #2Taking out (Extraction)

2Stability of the object's composition

If conventional planar pressure bulkhead designs with foam or honeycomb cores and multiple structural elements are used, then structural rigidity is improved, but weight increases

Engineering Contradiction:

Improvestructural rigidityVSAvoidweight

Core Design Contradiction:

Stability of the object's compositionVSWeight of moving object

Solution Approach 1:

The patent employs thin planar wall structures that leverage shell theory principles to achieve high rigidity-to-weight ratios. The circumferential monolithic reinforcing elements provide additional stiffness where needed while maintaining an overall lightweight construction, eliminating the need for heavy foam or honeycomb core materials.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The monolithic sandwich structure functions as a composite construction with two planar walls separated by circumferential reinforcing elements, creating a lightweight yet rigid assembly that outperforms conventional single-material constructions in terms of strength-to-weight and rigidity-to-weight ratios.

Inventive Principle:

Principle #40Composite materials

3Strength

If spherical or bubble-shaped membranes are used for pressure bulkheads, then bending strain is reduced, but cabin space is significantly restricted

Engineering Contradiction:

Improvebending strain reductionVSAvoidcabin space

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

While maintaining the beneficial curvature principles of spherical designs, the patent applies localized circumferential reinforcing elements to the planar walls to provide the necessary strength and load distribution. This allows the bulkhead to achieve spherical-like stress distribution characteristics while maintaining a flat profile that maximizes cabin space.

Inventive Principle:

Principle #14Spheroidality (Curvature)

4Strength

If complex connection devices with multiple structural elements are used, then load distribution is improved, but assembly complexity and time increase

Engineering Contradiction:

Improveload distributionVSAvoidassembly time

Core Design Contradiction:

StrengthVSLoss of time

Solution Approach 1:

The integrated monolithic sandwich structure combines load distribution functions into a single assembly unit that can be installed as one piece, eliminating the need for complex on-site assembly of multiple separate structural elements while maintaining effective load distribution across the bulkhead.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS11273895B2Planar pressure bulkhead for an air- or spacecraft and air- or spacecraft

Publication Date: 2022.03.15 AIRBUS OPERATIONS GMBH

AI summary

A planar pressure bulkhead for an air- or spacecraft, including a first planar wall designed as a pressure seal for a fuselage structure, a second planar wall arranged opposite the first wall, and a reinforcing structure which is arranged between the first and the second wall and which includes at least one circumferential monolithic reinforcing element. Furthermore, the present disclosure provides an air- or spacecraft, including a fuselage structure and a planar pressure bulkhead that is coupled to the fuselage structure in a circumferentially continuous manner.