Adaptive Composite Wing Surface with Shape Memory Alloys
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Solution Overview
Problem
Conventional aircraft flight control surfaces require separate structural and actuation components, leading to increased weight and cost, and lack the ability to change shape without separate actuation systems.
Innovation Solution
Integration of thermoplastic and shape memory alloy (SMA) materials to form an adaptive composite structure that can change shape in response to temperature changes, eliminating the need for separate actuation systems by using overbraiding or wrapping these materials around a mandrel and consolidating them using induction heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If separate structural and actuation components are used in conventional flight control surfaces, then structural integrity and actuation functionality are achieved, but weight and device complexity increase
Solution Approach 1:
The patent combines structural and actuation functions into a single integrated component by embedding shape memory alloy (SMA) wires directly into the composite material layers of the flight control surface. This eliminates separate actuation mechanisms and reduces overall weight while maintaining structural integrity.
Solution Approach 2:
The invention uses composite materials consisting of thermoplastic matrix with embedded shape memory alloy wires. This composite structure provides both structural strength and shape-changing capability, resolving the contradiction between structural requirements and actuation functionality.
2Adaptability or versatility
If conventional flight control surfaces use separate actuation systems, then shape change capability is achieved, but cost and device complexity increase
Solution Approach 1:
The shape memory alloy wires provide self-contained actuation capability within the composite structure. When electrically heated, the SMA wires autonomously change shape, causing the entire flight control surface to deform without requiring external actuation systems.
Solution Approach 2:
The patent replaces traditional mechanical actuation systems with electromagnetic heating of shape memory alloy wires. This substitution eliminates complex mechanical linkages, motors, and control systems while achieving the same shape-changing function through thermal-mechanical coupling.
3Weight of moving object
If integrated adaptive composite structure is used, then weight and cost are reduced, but manufacturing complexity increases
Solution Approach 1:
The shape memory alloy wires are pre-positioned and embedded within the composite material layers before final consolidation. This preliminary placement ensures proper spatial distribution and orientation of the actuation elements, simplifying the overall manufacturing process despite the integrated design.
Solution Approach 2:
The manufacturing process utilizes temperature parameter changes to consolidate the thermoplastic matrix and set the shape memory alloy wires in their desired configurations. By controlling thermal parameters during fabrication, the complex integrated structure is formed in a controlled manner.
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
The adaptive composite structure allows for a multifunctional flight control surface that can alter its shape without additional actuation, reducing weight and cost while enhancing aerodynamic control.
Implementation Method 1
an adaptive composite structure using shape memory alloys
Implementation Method 2
consolidating and forming the layers surrounding the expandable mandrel in an induction heating tool assembly
Implementation Method 3
smart susceptor which lies adjacent to the SMA actuator, which smart susceptor in turn is heated due to eddy currents induced in the smart susceptor by an alternating magnetic field
Data Source
AI summary
Systems and processes that integrate thermoplastic and shape memory alloy materials to form an adaptive composite structure capable of changing its shape. For example, the adaptive composite structure may be designed to serve as a multifunctional adaptive wing flight control surface. Other applications for such adaptive composite structures include in variable area fan nozzles, winglets, fairings, elevators, rudders, or other aircraft components having an aerodynamic surface whose shape is preferably controllable. The material systems can be integrated by means of overbraiding (interwoven) with tows of both thermoplastic and shape memory alloy materials or separate layers of each material can be consolidated (e.g., using induction heating) to make a flight control surface that does not require separate actuation.