Blind Interface Joint for Monolithic Aircraft Spar Assemblies
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Solution Overview
Problem
Aircraft components with high aspect ratios present challenges in joining due to mechanical strength requirements and the difficulty in using mechanical fasteners, especially when different materials are involved.
Innovation Solution
A monolithic structure with a Y-shaped spar fitting end and a fitting element with blades that mate within the channel of the spar fitting end, allowing for a bonded joint without mechanical fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners (screws, bolts) are used to join components, then mechanical strength is improved, but the complexity of the joint and difficulty of installation increase
Solution Approach 1:
The patent replaces mechanical fastening systems (screws, bolts) with a bonded joint system using adhesive materials. The fitting element and component are joined through chemical bonding rather than mechanical interlocking, eliminating the need for threads, holes, and fastener installation while maintaining structural strength.
Solution Approach 2:
The invention extracts and removes the mechanical fastener elements from the joint system. By designing a fitting element with integrated bonding surfaces and channels for adhesive distribution, the patent eliminates screws, bolts, and associated hardware, simplifying the overall joint structure.
2Strength
If mechanical fasteners are used in high aspect ratio components, then mechanical strength is improved, but the difficulty of installation and accessibility increases
Solution Approach 1:
The patent replaces complex mechanical fastening operations with a simpler bonded joint process. The fitting element design includes features that facilitate adhesive application and distribution, allowing installation without the need for precise hole alignment, threading, or fastener tightening operations that are difficult in high aspect ratio components.
Solution Approach 2:
The fitting element is pre-designed with integrated bonding surfaces and internal channels for adhesive distribution. This preliminary configuration of bonding features eliminates the need for on-site mechanical fastener installation, allowing the joint to be formed through simpler adhesive application and curing processes.
3Adaptability or versatility
If different materials (metallic and non-metallic) are joined, then design flexibility is improved, but the difficulty of achieving satisfactory joint strength increases
Solution Approach 1:
The patent introduces an adhesive material as an intermediary substance between dissimilar materials (metallic and non-metallic components). This adhesive mediator creates a chemical bond that bridges the interface between incompatible materials, allowing strength to be achieved through chemical adhesion rather than mechanical interlocking, which would be difficult across material boundaries.
Solution Approach 2:
The invention employs composite joint structures where the adhesive material creates a composite interface between dissimilar base materials. The fitting element itself may be constructed as a composite structure combining different materials to optimize bonding surfaces for various substrate types, enabling satisfactory joint strength across material boundaries.
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 solution provides a lightweight, strong, and durable joint that meets mechanical strength requirements without the need for internal mechanical fasteners, suitable for high-aspect ratio aircraft components.
Implementation Method 1
The one or more blades are bonded to the one or more spar fitting ends
Data Source
AI summary
A component is provided that includes a monolithic structure and a fitting element. The monolithic structure includes first and second outer panels, and spars disposed between the first and second outer panels. The width of the monolithic structure extends between a fitting end and a distal end. The spars extend widthwise between the first and second outer panels. The spar fitting end of each spar has a Y-shaped configuration with first and second finger walls, and a channel disposed there between. Both the first and second finger walls have a divergent end and a distal end. The channel has a closed end and an open end defined at the finger wall distal ends. The fitting element has a body with one or more blades extending outwardly therefrom. Each blade is received in and mates with a spar fitting end channel and is bonded to the spar fitting end.