Double-Wall Aircraft Leading Edge for Lightweight Flow Control
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Solution Overview
Problem
Existing leading edge structures for aircraft flow control systems, particularly Hybrid Laminar Flow Control (HLFC) systems, are complex and heavy due to separate components that need to be mounted together, increasing weight and complexity.
Innovation Solution
The leading edge structure integrates stiffeners with the inner wall element, eliminating the need for fasteners and simplifying manufacturing through Resin Transfer Molding (RTM), with a double-walled design featuring micro pores and throttle holes for fluid control, and using CFRP and titanium materials for lightweight yet strong construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If separate components are used for stiffeners and inner wall element, then assembly flexibility is improved, but weight increases and manufacturing complexity increases
Solution Approach 1:
The stiffeners are formed integrally with the inner wall element as a single monolithic component, eliminating the need for separate stiffener components and fasteners. This merging of components reduces the overall weight by removing redundant fastening elements while maintaining the structural reinforcement function of the stiffeners.
2Ease of repair
If separate components are used for stiffeners and inner wall element, then ease of repair is improved, but device complexity increases
Solution Approach 1:
The inner wall element and stiffeners are manufactured as a single integrated component using RTM technology, eliminating multiple separate parts. This reduces device complexity by removing the need for multiple components and their associated fasteners, while the modular panel design maintains repairability at the panel level.
Solution Approach 2:
The manufacturing process parameters are changed from traditional multi-component assembly to integral RTM manufacturing, producing a monolithic structure that simplifies the overall device complexity while maintaining functional requirements.
3Manufacturing precision
If traditional manufacturing methods are used, then manufacturing precision is maintained, but productivity decreases
Solution Approach 1:
The manufacturing process transitions from traditional multi-step assembly methods to integral RTM manufacturing, changing the process parameters to enable single-step production of the integrated inner wall element and stiffeners, thereby improving productivity while maintaining precision through controlled resin injection and curing parameters.
Solution Approach 2:
The stiffeners are pre-formed as integral parts of the inner wall element during the RTM molding process itself, eliminating subsequent assembly steps. This preliminary formation of the complete structure in one manufacturing operation significantly improves productivity while ensuring precise geometric accuracy through mold-controlled dimensions.
4Weight of moving object
If integral construction is used, then weight is reduced, but manufacturing complexity increases
Solution Approach 1:
The inner wall element and stiffeners are combined into a single monolithic component manufactured through RTM, reducing weight by eliminating fasteners and joint materials. The RTM process manages the manufacturing complexity by using pre-designed molds and controlled resin infusion to create the integrated structure in one 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 approach results in a simpler, lighter, and more mechanically robust leading edge structure with reduced material usage, enabling weight savings and improved manufacturing efficiency while maintaining control over air mass flow rates.
Implementation Method 1
The outer wall element comprises a plurality of micro pores, such as perforations, forming a fluid connection between the hollow chambers and the ambient flow over the outer surface of the outer wall element
Implementation Method 2
The inner wall element comprises openings forming a fluid connection between the hollow chambers and the plenum
Data Source
AI summary
A leading edge structure (1) for a flow control system of an aircraft, including a double-walled leading edge panel (3) that surrounds a plenum (7), wherein the leading edge panel (3) includes an inner wall element (21) facing the plenum (7) and an outer wall element (23) in contact with the ambient flow (25), wherein between the inner and outer wall elements (21, 23) the leading edge panel (3) includes elongate stiffeners (27) spaced apart from one another, so that between each pair of adjacent stiffeners (27) a hollow chamber (29) is formed between the inner and outer wall elements (21, 23), wherein the outer wall element (23) includes micro pores (31) forming a fluid connection between the hollow chambers (29) and an ambient flow (25), and wherein the inner wall element (21) includes openings (33) forming a fluid connection between the hollow chambers (29) and the plenum (7).