Fiber-Reinforced Thermoplastic Shearweb Injection Molding

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Solution Overview

Problem

Current methods for manufacturing aircraft skin attachment elements, such as shearwebs, clips, and rib stabilization elements, are labor-intensive and costly due to multi-step processes and require edge sealing to prevent corrosion, limiting efficiency and increasing production time.

Innovation Solution

An injection molding method using a fiber-reinforced thermoplastic composition is employed to produce primary-structure connection elements, allowing for the simultaneous creation of components like shearwebs and frame stabilization elements in a single process, eliminating the need for edge sealing and reducing production time and costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional multi-step manufacturing method is used for clips and cleats, then component shape precision can be achieved, but labor intensity and manufacturing cost increase significantly

Engineering Contradiction:

Improvecomponent shape precisionVSAvoidlabor intensity

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines multiple manufacturing steps (forming, cutting, sealing) into a single injection molding process. The mold is designed with integrated cooling channels and ejection systems that simultaneously complete all operations in one continuous process, eliminating the need for separate sealing and cutting steps that traditionally required manual labor

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent replaces manual mechanical operations (sealing edges by hand, cutting protrusions with saws) with automated injection molding machinery. The injection molding process automatically forms the complete component shape, includes integrated cooling, and produces ready-to-use parts without manual intervention in intermediate steps

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If traditional manufacturing method with separate sealing step is used, then edge sealing can be achieved, but production time and manufacturing cost increase

Engineering Contradiction:

Improvecorrosion protectionVSAvoidproduction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent performs the sealing action during the formation process itself rather than as a subsequent step. The injection molding process creates a fully sealed component structure in the primary forming operation, including integrated cooling channels that are sealed within the molded part, eliminating the need for separate post-production sealing steps

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the sealing operation with the primary forming operation. The mold design includes integrated cooling channels and sealing structures that are formed simultaneously with the main component body in a single injection molding cycle, eliminating sequential operations

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If traditional multi-step process is used for clips and cleats, then component functionality can be achieved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvecomponent functionalityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent creates a universal injection molding process that can produce multiple component types (clips, cleats, and variations) using the same basic mold design and process parameters. The standardized injection molding approach allows for easy adaptation to different component configurations without requiring fundamentally different manufacturing processes for each variant

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 labor and material costs by producing lightweight, high-modulus components quickly, with a potential 50% reduction in unit prices and enabling the integration of additional stabilization elements, while ensuring no fiber dry-out and minimizing corrosion risks.

Implementation Method 1

injecting the fiber-reinforced thermoplastic composition into an injection molding device

Methodology Applied

Scientific EffectInjection molding:

Data Source

PatentUS10150554B2Injection molding method for the manufacture of a primary-structure connection element

Publication Date: 2018.12.11 AIRBUS OPERATIONS GMBH

AI summary

An aircraft including a primary-structure connection element for attaching the aircraft skin to the primary structure of the aircraft is provided. The primary-structure connection element is designed as a shearweb, a clip and/or as a frame stabilization element or as a rib stabilization element and is manufactured from a fiber-reinforced thermoplastic material with the use of injection molding. Likewise, an injection molding method for the manufacture of such a primary-structure connection element is provided, in which method the fiber-reinforced thermoplastic material is injected in its melted state into an injection molding device. The manufactured shearweb etc. is removed from the injection molding device. In this method, in particular, chopped carbon fibers and/or glass fibers in combination with polyphenylene sulfide (PPS) and/or polyetherether ketone (PEEK) are used, for example also in pellet form.