Adhesive Bonding Airframe Members Solid Insert
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Solution Overview
Problem
The assembly of torque box structures in conventional tiltrotor aircraft wings is complex due to tight tolerances and limited access, making the installation of fasteners difficult, and the thickness of stringers reduces space for fuel and internal systems.
Innovation Solution
The use of large cell core stiffened panels with solid inserts provides a lightweight, high-stiffness structure that simplifies assembly by using composite materials with matching thermal expansion coefficients, eliminating the need for conventional stringers and improving structural bonding for enhanced stiffness and fuel bay clearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional stringers and multiple internal support members are used to provide stiffness and structural strength, then structural strength is improved, but the thickness of these members reduces the space available for fuel and internal systems
Solution Approach 1:
The patent combines the functions of multiple internal support members into a single integrated large cell core structure. This core structure provides the necessary stiffness and structural strength while occupying less space, thereby increasing the volume available for fuel and internal systems within the torque box structure.
Solution Approach 2:
The large cell core structure is strategically positioned and dimensioned to provide local stiffness and support exactly where needed in the torque box structure, rather than using multiple distributed support members. This localized approach maintains structural integrity while minimizing space consumption.
2Strength
If numerous fasteners are installed to secure structural members and provide stiffness, then structural strength is improved, but the installation becomes difficult and time consuming due to limited access and complicated sealing requirements
Solution Approach 1:
The patent extracts the need for numerous fasteners by designing the large cell core structure to be integrated with the skin and support members. This integration eliminates multiple separate fastening operations, simplifying assembly while maintaining structural strength through the unified construction.
Solution Approach 2:
The patent merges the functions of multiple fastened components into a single integrated large cell core structure. By combining the skin, support members, and core into one assembled unit rather than multiple fastened parts, the assembly process becomes simpler and less time-consuming while maintaining structural integrity.
3Strength
If multiple internal support members are used to provide horizontal structural strength, then structural strength is improved, but the device complexity and number of components increase
Solution Approach 1:
The patent merges multiple internal support members into a single large cell core structure that provides the same horizontal structural strength. This consolidation reduces the number of components from multiple separate support members to one integrated core, thereby reducing device complexity while maintaining structural performance.
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 solution reduces manufacturing complexity, weight, and cost, while improving structural strength and reducing quality defects, allowing for easier assembly and increased internal space within the torque box structure.
Implementation Method 1
an adhesive joint is disposed between the first and second surfaces structurally bonding the first airframe member to the second airframe member
Data Source
Figure 1A~1B
Figure 2
Figure 3~5B
AI summary
An airframe assembly (50) for an aircraft (10). The airframe assembly (50) includes a first airframe member (214) having a first skin (202), a second skin (210), a large cell core (204) joined between the first (202) and second (210) skins and a solid insert (208) having a side surface. The solid insert (208) is joined between the first (202) and second (210) skins such that at least a portion of the side surface is adjacent to the large cell core (204). The first skin (202) has a first surface disposed opposite the solid insert (208). The airframe assembly (50) also includes a second airframe member (220) having a second surface (224). An adhesive joint (226) is disposed between the first and second (224) surfaces structurally bonding the first airframe member (214) to the second airframe member (220) such that the second airframe member (224) is positioned opposite the solid insert (208).