Thermoplastic Multi-Grid Fuselage Structure
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Solution Overview
Problem
Conventional aircraft construction methods involving frameworks of stringers and frames are costly, time-consuming, and weight-intensive due to complex contour formation, intricate pattern requirements, and the need for fasteners, which also complicate the integration of openings and penetrations.
Innovation Solution
A thermoplastic multi-grid overmolded/co-consolidated aircraft fuselage structure using intersecting thermoplastic composite strips joined to an interior surface of a thermoplastic composite fuselage skin panel through overmolding and/or co-consolidation, simplifying the construction process and reducing assembly time and weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional frameworks of stringers and frames are used, then structural support is provided, but construction time and cost increase significantly
Solution Approach 1:
The patent combines the skin panel and framework into a single integrated composite structure manufactured through co-consolidation or overmolding processes. The framework elements (stringers and frames) are embedded within the skin panel during a single manufacturing operation, eliminating the need for separate assembly steps and reducing construction time while maintaining structural support.
Solution Approach 2:
The framework elements are pre-formed with complementary surfaces that will mate with the skin panel during co-consolidation or overmolding. This preliminary preparation allows the framework to be integrated into the final structure without requiring complex assembly operations, thereby reducing construction time while preserving structural integrity.
2Strength
If conventional frameworks of stringers and frames are used, then structural support is provided, but manufacturing cost increases
Solution Approach 1:
The patent combines the skin panel and framework into a single integrated composite structure manufactured through co-consolidation or overmolding processes. The framework elements (stringers and frames) are embedded within the skin panel during a single manufacturing operation, eliminating the need for separate assembly steps and reducing construction time while maintaining structural support.
Solution Approach 2:
The patent extracts the framework elements from the traditional separate-component approach and integrates them directly into the skin panel manufacturing process. By taking out the framework assembly step and incorporating it into the molding process, the overall manufacturing complexity and cost are reduced while maintaining structural support functionality.
3Strength
If fasteners are used to connect stringers, frames and skins, then structural connections are achieved, but assembly time and weight increase
Solution Approach 1:
The patent combines the skin panel and framework into a single integrated composite structure manufactured through co-consolidation or overmolding processes. The framework elements (stringers and frames) are embedded within the skin panel during a single manufacturing operation, eliminating the need for separate assembly steps and reducing construction time while maintaining structural support.
Solution Approach 2:
The patent replaces the mechanical fastening system with a chemical bonding approach through resin infusion or overmolding. The thermoplastic or thermoset resin creates strong adhesive bonds between the framework elements and skin panel, eliminating the need for mechanical fasteners and reducing both assembly time and overall structure weight.
4Strength
If fasteners are used to connect stringers, frames and skins, then structural connections are achieved, but aircraft weight increases
Solution Approach 1:
The patent replaces the mechanical fastening system with a chemical bonding approach through resin infusion or overmolding. The thermoplastic or thermoset resin creates strong adhesive bonds between the framework elements and skin panel, eliminating the need for mechanical fasteners and reducing both assembly time and overall structure weight.
Solution Approach 2:
The patent combines the skin panel and framework into a single integrated composite structure manufactured through co-consolidation or overmolding processes. The framework elements (stringers and frames) are embedded within the skin panel during a single manufacturing operation, eliminating the need for separate assembly steps and reducing construction time while maintaining structural support.
5Strength
If intricate patterns are used in framework construction, then structural requirements are met, but engineering time and tooling cost increase
Solution Approach 1:
The patent changes the manufacturing parameters from traditional separate fabrication and assembly to integrated co-consolidation or overmolding processes. This parameter change allows intricate framework patterns to be created directly within the mold during skin panel manufacturing, eliminating the need for separate tooling and engineering efforts for framework fabrication while maintaining structural requirements.
6Adaptability or versatility
If window openings or circular openings are integrated into rectangular framework, then openings are created, but additional reinforcement and assembly time are required
Solution Approach 1:
The patent combines the skin panel and framework into a single integrated composite structure manufactured through co-consolidation or overmolding processes. The framework elements (stringers and frames) are embedded within the skin panel during a single manufacturing operation, eliminating the need for separate assembly steps and reducing construction time while maintaining structural support.
Solution Approach 2:
The patent prepares the mold with pre-formed opening configurations that accommodate windows or circular openings during the co-consolidation or overmolding process. This preliminary mold preparation allows openings to be integrated into the structure without requiring post-manufacturing reinforcement or assembly operations, thereby reducing assembly time while maintaining adaptability for various opening configurations.
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 significantly reduces construction time and cost while enhancing structural integrity by eliminating the need for intricate frameworks and fasteners, allowing for efficient assembly of large fuselage sections and integration of openings without additional weight or complexity.
Implementation Method 1
The heat of the overmolding material causes contacting portions of the interior surface of the skin panel and the plurality of strips to melt, fusing together the contacting portions of the interior surface of the skin panel and the plurality of strips
Implementation Method 2
A heated, liquefied overmolding material is then injected into the mold. The overmolding material flows through the mold and extends between the interior surface of the skin panel and the plurality of strips on the interior surface of the skin panel
Data Source
AI summary
An aircraft structure and its method of construction avoids the inefficiencies involved in current methods of constructing the aircraft structure, reduces the manufacturing time required for constructing the aircraft structure and reduces the cost involved in constructing the aircraft structure. The aircraft structure and its method of construction is comprised of a geodesic or multi-grid framework of intersecting thermoplastic composite strips that are joined to an interior surface of a thermoplastic composite fuselage skin panel through overmolding/co-consolidation of the grid framework and the skin panel.