Aircraft Composite Shielded Structure Impact Absorption
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Solution Overview
Problem
Composite structures in aircraft face integrity issues due to damage to outer skins, requiring frequent inspections and repairs, and existing designs do not effectively absorb impact energy to protect the primary inner skin.
Innovation Solution
A composite structure with a thinner outer skin and a thicker inner skin, enclosing a core structure, where the outer skin is designed to absorb impact energy and sustain local damage without compromising structural integrity, using materials like foam or honeycomb to separate the skins and provide a shear load path, allowing for visual indication of damage and reduced repair needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a traditional sandwich structure with outer and inner skins is used, then the structure provides good stiffness-to-weight and strength-to-weight ratios, but the outer skin is vulnerable to damage requiring frequent inspections and repairs
Solution Approach 1:
The patent divides the traditional single-skin structure into multiple skin layers (first outer skin, second outer skin, and inner skin) with a core structure between them. This segmentation allows the outer skins to serve as protective shields that absorb impact energy before it reaches the load-carrying inner skin, reducing damage frequency and inspection requirements while maintaining overall structural strength.
2Object-affected harmful factors
If the outer skin is made thicker to absorb impact energy, then damage protection improves, but the overall structure weight increases
Solution Approach 1:
The patent employs composite material construction with multiple skin layers and core structure (foam or honeycomb) to create a lightweight yet energy-absorbing outer shell. The composite structure provides superior impact energy absorption compared to solid materials of equivalent weight, as the core structure dissipates energy through deformation while the multi-layer skin configuration distributes impact forces, achieving protection without excessive weight penalty.
3Reliability
If frequent inspections and repairs of the outer skin are performed, then structural integrity is maintained, but operational costs and downtime increase
Solution Approach 1:
The patent implements a protective outer skin system designed to absorb impact energy before it can damage the load-carrying inner skin. This beforehand cushioning approach prevents damage rather than merely detecting and repairing it, significantly reducing the frequency of inspections and repairs needed while maintaining structural integrity, thereby improving operational efficiency by reducing downtime and maintenance costs.
4Strength
If the outer skin is designed to carry substantial load, then structural strength is improved, but the skin becomes more susceptible to damage from impacts
Solution Approach 1:
The patent applies different functional qualities to different skin layers: the outer skins are optimized for impact resistance and energy absorption with appropriate thickness and material properties, while the inner skin is optimized for load-carrying capacity with higher strength-to-weight ratio materials and configurations. This local differentiation allows each layer to excel at its specific function without compromising overall structural performance.
Data Source
AI summary
An aircraft includes a composite structure, comprising an outer skin formed from a composite material and having a first thickness, an inner skin formed from a composite material and having a second thickness, the second thickness being greater than the first thickness, and a core structure positioned between the inner and outer skins to increase bending stiffness of the composite structure. During use a structural load carried by the inner skin exceeds a structural load carried by the outer skin.