Reinforced Shell Element Manufacturing with Interlocking Support Recesses
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Solution Overview
Problem
Existing methods for manufacturing shell elements reinforced with support elements, such as those used in aircraft structures, are inefficient and time-consuming when attempting to cross-support elements in both longitudinal and transverse directions without weakening the structure or interrupting force transmission.
Innovation Solution
A method involving the attachment of support elements with recesses and projections allows for the simple and rapid application of transversely oriented support elements on a skin element, using prepreg layers to secure them without compromising structural integrity, enabling equal stiffness in both directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If support elements are arranged in a grid pattern using spacers, then both longitudinal and transverse support elements can be provided, but the manufacturing process becomes very tedious and time-consuming
Solution Approach 1:
The support elements are provided with recesses and projections in advance during manufacturing. These pre-formed geometric features enable quick interlocking during assembly without requiring time-consuming placement of separate spacers or complex positioning operations, thus resolving the contradiction between achieving bidirectional support and maintaining manufacturing efficiency
Solution Approach 2:
The recesses and projections act as intermediary geometric features that facilitate the connection between crossing support elements. These pre-designed interlocking features serve as mediators that enable rapid assembly of the grid pattern without requiring additional components like spacers, thereby improving productivity while maintaining structural versatility
2Ease of manufacture
If support elements cross over each other without recesses and projections, then the structure appears simple, but the force transmission is interrupted and structural integrity is weakened
Solution Approach 1:
Instead of modifying the entire support element structure, recesses and projections are introduced only at the specific locations where support elements cross each other. This localized modification maintains the overall simplicity of the support elements while providing critical force transmission paths at the intersection points, thus resolving the contradiction between manufacturing simplicity and structural strength
Solution Approach 2:
The support elements are formed as composite structures incorporating both solid material and voids (recesses). This composite design allows the elements to maintain their primary structural function while providing interlocking features at crossing points, enabling both ease of manufacture and continuous force transmission
3Productivity
If traditional methods are used to attach support elements, then the process is straightforward for longitudinal elements, but adding transverse elements requires complex spacer placement and removal
Solution Approach 1:
The invention extracts and eliminates the need for separate spacer components by integrating the positioning and support functions directly into the support elements themselves through recesses and projections. This reduction in component count simplifies the manufacturing process and improves productivity by removing the tedious steps of spacer placement and removal
Solution Approach 2:
The support and positioning functions, previously separated into distinct components (support elements and spacers), are merged into a single integrated support element design. The recesses and projections combine the structural support role with the positioning and interlocking role, eliminating the need for separate spacer components and simplifying the overall manufacturing process
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 method allows for the quick and efficient application of support elements that cross over each other without weakening the structure, ensuring equal durability and stiffness in both longitudinal and transverse directions, thereby enhancing the manufacturing process for shell elements.
Implementation Method 1
prepreg layers are placed on the lateral surfaces of the support elements, on both sides and in the form of angle brackets, and on the inner surface of the skin element, wherein, finally, said prepreg layers are cured by means of an externally applied pressure and a certain temperature
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Method for manufacturing a shell element (5) reinforced with support elements (1, 3), having the following steps of: (a) providing a skin element (7), which has an outer surface (9) and an inner surface (11) opposite the outer surface (9), (b) providing a first support element (1), which has an attaching side (15) and a free side (17) is opposite the attaching side (15), (c) attaching the first support element (1) on the skin element (7) such that the attaching side (15) of the first support element (1) faces the inner surface (11) of the skin element (7), (d) introducing a first recess (25) into the first support element (1), which proceeds from the free side (17) of the first support element (1) and extends transversely to the first axis (13), (e) providing a second support element (3), which has a support side (35) and a front side (37) opposite the support side (35), (f) inserting the second support element (3) into the first recess (25) of the first support element (1) such that the support side (35) faces the inner surface (11) of the skin element (7), and (g) attaching the second support element (3) on the first support element (1) and/or on the skin element (7).