Overbraided Composite Duct Assembly for Complex Aircraft Geometries
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Solution Overview
Problem
Existing duct structures for aircraft propulsion systems, particularly those made from fiber-reinforced composites, face challenges in manufacturing efficiency and integration, lacking a robust method for forming complex geometries and ensuring structural integrity while accommodating acoustic and anti-icing requirements.
Innovation Solution
A method involving the use of woven fiber sleeves over mandrels, infused with polymer material, to form duct sections that can be attached and integrated to create a monolithic fiber-reinforced composite duct structure, including acoustic structures and anti-icing systems, using techniques like overmolding and mechanical fastening or welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional duct structures are manufactured using conventional methods, then manufacturing simplicity is maintained, but manufacturing efficiency and structural integrity for complex geometries deteriorate
Solution Approach 1:
The duct structure is divided into multiple modular sections, each formed independently using woven fiber sleeves over mandrels. These sections can be manufactured separately and then assembled together, enabling complex overall geometries while maintaining efficient production of individual components through standardized forming processes
Solution Approach 2:
The duct structure utilizes fiber-reinforced composite materials formed by impregnating woven fiber sleeves with polymer resin. This composite construction provides enhanced structural integrity and enables complex geometries that would be difficult to achieve with traditional materials, while the modular assembly approach maintains manufacturing efficiency
2Strength
If duct structures are formed as monolithic pieces, then structural integrity is improved, but manufacturing flexibility and efficiency deteriorate
Solution Approach 1:
The duct is segmented into multiple sections that are manufactured separately using woven fiber sleeves and then assembled through attachment mechanisms. This segmentation maintains structural integrity at the joints while providing manufacturing flexibility for complex geometries and enabling parallel production of multiple sections
Solution Approach 2:
One duct section is inserted through an opening in another duct section, creating a nested arrangement. This nesting configuration maintains structural continuity and integrity while allowing modular assembly and disassembly, providing both strength and manufacturing flexibility
3Object-affected harmful factors
If acoustic structures are added to duct sections, then acoustic performance is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The acoustic structure is merged with the duct section by forming the acoustic material as an integral part of the duct wall during the same manufacturing process. This combining approach improves acoustic performance while avoiding the need for separate acoustic components, thereby reducing overall device complexity
Solution Approach 2:
Acoustic material is incorporated into the composite structure of the duct section, creating a multi-functional composite component that provides both structural and acoustic functions. This integration improves acoustic performance while maintaining manufacturing efficiency through a single forming process
Data Source
AI summary
A method is provided for manufacturing during which a first duct section is formed with a tubular first sidewall. A first opening extends through the tubular first sidewall. The forming of the first duct section includes disposing a first woven fiber sleeve over a first mandrel and disposing a polymer material with the first woven fiber sleeve. A second duct section is disposed with a tubular second sidewall. The forming of the second duct section includes disposing a second woven fiber sleeve over a second mandrel and disposing the polymer material with the second woven fiber sleeve. The second duct section is arranged with the first duct section. The second duct section engages the tubular first sidewall. The tubular second sidewall is located at and extends circumferentially around the first opening. A duct structure is formed by attaching the second duct section to the first duct section.