Aerodynamic Profile with Composite Reinforced Oblong Foam Core
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Solution Overview
Problem
The construction of aerodynamic profiles for aircraft is complex, heavy, and costly due to the need for complex shapes and mechanical stress resistance, with existing composite materials not optimally addressing mechanical characteristics and mass issues.
Innovation Solution
An aerodynamic profile featuring a hollow core made of composite material reinforced with unidirectional fibers, combined with a skin that defines the outer surface, providing a lightweight and mechanically optimized structure capable of reacting shear stresses, with optional transverse beams and foam filling for enhanced stiffness and reinforcement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a riveted metallic skin covering a metallic frame with ribs, spars, and stiffeners is used to construct an aerodynamic profile, then the profile can withstand mechanical stresses, but the profile becomes heavy and complex
Solution Approach 1:
The patent replaces traditional metallic structures with composite materials consisting of a hollow core made of foam material (such as polyurethane or polyester foam) reinforced with unidirectional fibers oriented at specific angles (0°, ±45°, ±30°). This composite construction provides equivalent or superior mechanical strength while significantly reducing weight compared to riveted metallic assemblies.
Solution Approach 2:
The patent divides the profile into distinct functional zones: a hollow core made of foam material and a skin layer. The hollow core itself is segmented into different regions with fibers oriented at different angles to optimize stress distribution. This segmentation allows each zone to be optimized for its specific mechanical requirements while reducing overall complexity.
2Loss of energy
If the aerodynamic profile uses a complex shape to improve aerodynamic performance, then drag reduction and fuel consumption improve, but the construction becomes more complex and costly
Solution Approach 1:
The patent optimizes the aerodynamic profile by varying the orientation angles of unidirectional fibers in different regions of the hollow core. By changing the fiber orientation parameters (0° for longitudinal strength, ±45° for shear resistance, ±30° for diagonal reinforcement), the structure adapts to local stress distributions, enabling complex aerodynamic shapes to be constructed with optimized material placement rather than additional structural elements.
Solution Approach 2:
The patent applies different fiber orientation patterns in different regions of the hollow core according to local stress requirements. The skin layer and core structure are designed with locally optimized fiber arrangements that match the specific aerodynamic and structural demands of each profile section, allowing complex shapes to be achieved with efficient material usage.
3Weight of moving object
If traditional composite materials are used for the aerodynamic profile, then the profile can be made lightweight, but the mechanical characteristics and ability to react shear stresses are not optimized
Solution Approach 1:
The patent creates a multi-layer composite structure where unidirectional fibers are embedded in a foam core at specific orientations (0°, ±45°, ±30°). This composite arrangement specifically targets shear stress resistance by utilizing the ±45° fiber layers which are optimally oriented to resist shear loads, while the foam core provides lightweight structural support and distributes stresses uniformly.
Solution Approach 2:
The patent employs a hollow core with rounded contours rather than sharp angles, which helps distribute stress more evenly throughout the structure. The curved geometry of the foam core works synergistically with the oriented fiber layers to resist shear stresses while maintaining lightweight construction.
Data Source
AI summary
An aerodynamic profile including a skin defining the outer surface of the aerodynamic profile, a leading edge, a trailing edge and a central portion representing at least 50% of the chord of the profile. The profile includes a hollow core of composite material reinforced with a textile having unidirectional fibers. The hollow core has, in cross section, an oblong shape that is rounded, in particular at each of its ends. The skin bears against the hollow core over the length of the central portion of the aerodynamic profile, both on the pressure side and on the suction side of the profile. The reinforcement with a textile having unidirectional fibers permits an ideal orientation of reinforcing fibers in order to optimize mechanical properties in certain directions. The shape of the hollow core, elongate along the chord of the profile and rounded, lends it great resistance to deformation.