Aircraft Control Surface Co-Curing Process
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional assembly processes for aeronautical control surfaces, such as flaps and ailerons, are slow and cannot achieve a smooth surface due to the need for extensive riveting, which increases costs and fuel consumption.
Innovation Solution
An integrated co-curing process that simultaneously solidifies composite materials and adheres them to structural elements, reducing the need for subsequent riveting by producing skins with integrated structural elements and leading edges through a combined system of stiff and flexible tools in an autoclave.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional riveting processes are used to assemble control surfaces, then structural strength is ensured, but assembly time increases and surface smoothness deteriorates
Solution Approach 1:
The patent merges the skin and structural elements (spars, ribs, stringers) into a single integrated composite structure through co-curing. This eliminates the need for separate riveting operations to attach these components, thereby reducing assembly time while achieving a smooth continuous surface without rivet holes or protrusions.
Solution Approach 2:
The structural elements are pre-positioned within the mold before the skin material is applied and cured. This preliminary arrangement allows the skin to be formed directly over the structural elements during the co-curing process, eliminating subsequent riveting operations and ensuring surface smoothness from the outset.
2Ease of manufacture
If extensive riveting is performed to assemble control surfaces, then structural connection is achieved, but production costs increase
Solution Approach 1:
By combining multiple components (skin, spars, ribs, stringers) into a single integrated composite structure manufactured through co-curing, the patent eliminates numerous riveting operations. This reduction in assembly steps directly lowers production costs while simultaneously improving assembly speed.
3Use of energy by moving object
If traditional assembly processes are used, then structural elements can be connected, but fuel consumption increases due to aerodynamic drag
Solution Approach 1:
The integration of skin and structural elements into a seamless composite structure eliminates rivet holes and surface discontinuities. This creates a smooth aerodynamic surface that reduces drag, thereby lowering fuel consumption during aircraft operation.
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 process significantly reduces assembly time and allows for the creation of smooth control surfaces, lowering costs and fuel consumption by minimizing riveting and ensuring aerodynamic cleanliness.
Implementation Method 1
The skins are implemented with the structural elements and with the leading edges formed from a rolled section of composite material, by means of an adhesive layer, simultaneously to the solidification of the composite material
Implementation Method 2
simultaneously to the solidification of the composite material
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A process for assembling aircraft control surfaces (1, 1'), in particular high-lift devices and wing portions, allows implementing smooth control surfaces in short times, wherein the control surface is defined by an upper skin (2) and by a lower skin (9), the upper skin being destined to form the leading edge (4) of the control surface by means of the connection to a front spar (3), wherein the upper skin and the lower skin are made of a laminar composite material which, not yet hardened, is fastened to structural elements (3, 5, 6, 7) of the control surface by means of an adhesive; and wherein the resin of the composite material and the adhesive are hardened simultaneously in autoclave.