Beaded Composite Wing Structures for Integrated Routing

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Solution Overview

Problem

Traditional manufacturing methods for airplane wing components require separate fabrication of blade stringers and vent stringers, which are costly, time-consuming, and result in a structure that is heavy due to the use of many parts. Additionally, the space between the upper and lower portions of airplane wings is confined, making assembly and maintenance challenging.

Innovation Solution

The development of beaded composite structures, which consist of a first layer and a second layer connected to form a layered structure. The second layer features base portions abutting the first layer and beaded portions protruding from the base portions, creating channels between the layers. This design allows for the integration of system features like wires or conduits within these channels and facilitates easier access for maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If separate blade stringer and vent stringer fabrication is used, then structural integrity is maintained, but manufacturing cost and time increase

Engineering Contradiction:

Improvemanufacturing costVSAvoidnumber of parts

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines separate blade stringer and vent stringer fabrication into a single integrated beaded composite structure. The beaded portions integrate multiple stringer functions into one component, eliminating the need for separate fabrication and bonding steps, thereby reducing manufacturing cost and time while maintaining structural integrity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The beaded composite structure serves multiple functions simultaneously - it provides both blade stringer and vent stringer structural support, incorporates channels for system features, and enables maintenance access. This multi-functionality reduces the overall number of parts needed in the wing assembly

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If many parts are used in wing structure, then structural requirements are met, but overall weight increases

Engineering Contradiction:

Improvestructural integrityVSAvoidwing weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Multiple structural components (blade stringer, vent stringer) are merged into a single beaded composite structure, reducing the total number of parts and thereby decreasing overall wing weight while maintaining the required structural integrity through the integrated design

Inventive Principle:

Principle #5Merging (Combining)

3Ease of operation

If traditional assembly methods are used, then manufacturing simplicity is maintained, but maintenance accessibility deteriorates

Engineering Contradiction:

Improvemaintenance accessibilityVSAvoidassembly complexity

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The beaded composite structure incorporates internal channels that segment the space for routing system features like wires and conduits. These channels provide dedicated pathways that simplify both assembly and maintenance operations by organizing components within defined spaces, making it easier to access and service the wing structure

Inventive Principle:

Principle #1Segmentation

4Ease of repair

If confined space navigation is required, then assembly is completed, but maintenance time and difficulty increase

Engineering Contradiction:

Improvemaintenance timeVSAvoidaccessibility

Core Design Contradiction:

Ease of repairVSEase of operation

Solution Approach 1:

The beaded structure creates segmented channels within the wing assembly that provide organized pathways for system features. This segmentation allows maintenance personnel to access and service components more efficiently by providing defined routes through the wing structure, reducing maintenance time and difficulty

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The beaded portions protrude from the second layer, creating a three-dimensional channel network within the wing structure. This dimensional approach provides multiple access paths and routing options for system features, improving maintenance accessibility without increasing overall wing complexity

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentUS20250178716A1Beaded composite structures and methods for manufacturing beaded composite structures

Publication Date: 2025.06.05 THE BOEING CO

AI summary

A composite structure has a first layer connect to a second layer to form a layered structure. The second layer has a plurality of base portions abutting the first layer and a plurality of beaded portions protruding from the plurality of base portions. Each beaded portion of the plurality of beaded portions defines a channel between the first layer and the second layer. A method for manufacturing a composite structure includes depositing composite material over a tool to form a second layer. The second layer has a plurality of beaded portions and a plurality of base portions. The method includes distributing a plurality of mandrels over the second layer to define channels in the plurality of beaded portions. The method includes depositing composite material over the second layer and the plurality of mandrels to form a first layer. The method includes bonding the first layer to the second layer.