Overbraided Composite Duct Structure With Integrated Annular Flange
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current duct structures for aircraft propulsion systems, particularly those made from fiber-reinforced composites, face challenges in achieving a lightweight, complex design that balances structural integrity and manufacturing efficiency.
Innovation Solution
A method involving the use of a woven fiber sleeve over a mandrel to create an overbraided structure, with distinct sections forming a tubular duct and annular flanges, infused with polymer material, utilizing tooling to shape and reinforce the composite duct structure, which can include carbon fibers and thermoplastic or thermoset materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional duct structures are used for aircraft propulsion systems, then structural integrity is maintained, but weight reduction and design complexity are limited
Solution Approach 1:
The patent combines multiple duct sections and flanges into a single monolithic composite structure, eliminating the need for separate manufacturing and assembly of multiple components. This merging approach reduces overall weight while integrating complex geometries that would traditionally require multiple parts, thereby resolving the contradiction between weight reduction and manufacturing complexity.
Solution Approach 2:
The patent employs fiber-reinforced composite materials with polymer resin infusion to create a lightweight yet structurally intact duct structure. The composite material system provides high strength-to-weight ratio, enabling weight reduction while maintaining structural integrity. The complex woven fiber architecture allows formation of intricate shapes in a single manufacturing step, addressing both weight and complexity concerns.
2Device complexity
If complex monolithic composite structures are manufactured, then weight and complexity are reduced, but manufacturing precision and structural integrity become challenging to achieve
Solution Approach 1:
The patent incorporates flanges and mounting features directly into the mold during the composite forming process, ensuring precise geometry and positioning before the material sets. The mandrel and mold tools are pre-configured with exact dimensions and features, allowing the complex monolithic structure to be formed with high precision in a single operation, thereby achieving both structural complexity and manufacturing precision.
3Weight of moving object
If fiber-reinforced composite materials are used, then weight is reduced, but manufacturing process complexity increases
Solution Approach 1:
The patent employs automated resin infusion processes where the polymer material is drawn through the fiber preform by vacuum or pressure differential, eliminating the need for manual resin application. The process self-regulates resin flow and saturation, reducing labor intensity and simplifying manufacturing while maintaining the weight benefits of composite materials.
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 enables the production of a lightweight, monolithic fiber-reinforced composite duct structure that reduces complexity and weight while maintaining structural integrity, suitable for aircraft propulsion systems, with enhanced fluid flow management and durability.
Implementation Method 1
A polymer material is infused into the woven fiber sleeve to provide a duct structure
Implementation Method 2
A polymer material is disposed with the woven fiber sleeve to provide a duct structure
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A method is provided for manufacturing. During this method, a woven fiber sleeve (128) is disposed over a mandrel (130) to provide an overbraided mandrel (132). The woven fiber sleeve (128) includes a base section (138) and a mount section (144). The base section (138) is wrapped circumferentially around the mandrel (130) and extends longitudinally along the mandrel (130) between a first end (140) and a second end (142). The mount section (144) is disposed longitudinally at an intermediate location between the first end (140) and the second end (142). The mount section (144) projects out from the base section (138). The overbraided mandrel (132) is arranged with tooling (148). A polymer material is disposed with the woven fiber sleeve (128) to provide a duct structure (60). The duct structure (60) includes a tubular duct and an annular flange (96). The tubular duct is formed by the base section (138). The annular flange (96) is formed by the mount section (144).