Composite Bonded Panel Recess Machining for Lightweight Wing Structures

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Solution Overview

Problem

Aircraft structures, particularly wing assemblies, are costly and heavy due to the use of reinforcing stringers, ribs, and fasteners, which increase the overall weight and cost of the aircraft.

Innovation Solution

A method involving the orientation of composite material layers onto a tool to form a substrate, introducing a predetermined pattern area, and partially curing the substrate to create recesses, thereby reducing material weight and complexity while maintaining structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If reinforcing stringers, ribs, and fasteners are used in aircraft wing structures, then structural strength and rigidity are improved, but weight and cost increase

Engineering Contradiction:

Improvestructural strengthVSAvoidwing assembly weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent combines multiple discrete structural components (stringers, ribs, skin) into a single integrated composite panel with through-thickness recesses. This merging eliminates the need for separate reinforcing elements and fasteners, reducing weight while maintaining structural integrity through the engineered recess patterns that provide reinforcement where needed.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention uses composite materials with through-thickness recesses created by removing material from the core or honeycomb structure. These composite panels integrate reinforcement functions directly into the material architecture rather than relying on discrete metal fasteners andJoining elements, achieving strength reduction through material optimization.

Inventive Principle:

Principle #40Composite materials

2Reliability

If multiple discrete components (stringers, ribs, fasteners) are used, then structural integrity is maintained, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvestructural integrityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges multiple discrete structural components into a single integrated panel assembly. The through-thickness recesses are engineered to provide reinforcement functions that previously required separate stringers and ribs, eliminating the need for complex assembly of multiple parts and reducing overall device complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The invention segments the panel thickness into distinct regions with recesses at specific locations, creating a patterned structure that provides reinforcement where needed while maintaining simplicity in the overall design. This segmentation approach allows structural integrity to be achieved through strategic material removal rather than adding complex components.

Inventive Principle:

Principle #1Segmentation

3Strength

If traditional reinforcing structures are used, then structural strength is ensured, but fuel consumption increases due to higher weight

Engineering Contradiction:

Improvestructural strengthVSAvoidfuel consumption

Core Design Contradiction:

StrengthVSUse of energy by moving object

Solution Approach 1:

The invention uses composite materials with through-thickness recesses that reduce weight while maintaining structural strength. By optimizing the material architecture with patterned recesses, the panel achieves the required strength with less mass, directly reducing fuel consumption in aircraft applications.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the physical parameters of the structural panels by introducing through-thickness recesses at optimized locations and depths. This parameter modification reduces material usage and panel weight while maintaining strength, leading to lower fuel consumption in aircraft operations.

Inventive Principle:

Principle #35Parameter changes

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

The method achieves a significant weight reduction of up to 57% and enhances the stiffness-to-weight ratio of composite material substrates, potentially reducing fuel costs, increasing payload capacity, and simplifying manufacturing processes.

Implementation Method 1

at least partially curing the composite material substrate to form a predetermined amount of cured composite material substrate

Methodology Applied

Scientific EffectCuring: Photopolymerisation

Data Source

PatentUS12337994B2Integrally stiffened bonded panel with machined recesses and improved methods of manufacture

Publication Date: 2025.06.24 THE BOEING CO

AI summary

Methods for machining a composite material substrate are discloses comprising integrating a predetermined pattern area having a disbond material for the purpose of creating a disbond region into the composite material substrate at a predetermined thickness, detecting the disbond region and forming a plurality of recesses in the composite material substrate by removing a machined plug from the composite material substrate to form recesses positioned at locations corresponding to the predetermined pattern area, and composite components comprising the recesses machined according to such methods.