Braided Composite Energy Absorber for Aircraft Structural Integrity
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Solution Overview
Problem
Aircraft structural elements, particularly rotary components like blades and vanes, are vulnerable to high-energy impacts from debris during flight, leading to potential detachment and chain reactions that can cause aircraft crashes, necessitating a solution to absorb kinetic energy and maintain structural integrity.
Innovation Solution
Integration of a kinetic energy absorption device within aircraft structural elements, comprising a braided composite outer casing and a foam core with reinforcing dry composite fibers to dissipate impact energy, featuring a method of manufacturing that includes encapsulating preforms of dry composite fibers within the foam core and surrounding them with additional foam layers before installing the outer casing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional structural elements are used without energy absorption devices, then the structure maintains simplicity and lower weight, but it is vulnerable to high-energy impacts from debris causing detachment and breakup
Solution Approach 1:
The energy absorption device is nested within the structural element, with the foam core and reinforcing fibers contained inside the outer casing which is itself integrated into the structural element. This nested arrangement provides impact protection while maintaining a compact form factor and minimizing space requirements.
Solution Approach 2:
The invention employs composite materials at multiple levels: the outer casing uses braided composite material, the reinforcing elements use dry composite fibers, and these are combined with foam core material. This multi-layer composite structure provides superior impact resistance compared to conventional single-material structures.
2Reliability
If the structural element is designed to withstand high-energy impacts, then reliability improves, but the weight of the structural element increases
Solution Approach 1:
The energy absorption device is strategically positioned at specific locations within the structural element where impact protection is most needed, such as the leading edges or exposed surfaces. This localized approach provides targeted protection without requiring the entire structure to be reinforced, thereby minimizing weight increase.
Solution Approach 2:
The foam core material provides a porous structure that effectively absorbs impact energy through compression and deformation. This porous material offers high energy absorption capacity per unit weight, providing lightweight impact protection compared to solid alternative materials.
3Reliability
If passive energy absorption devices are integrated into structural elements, then kinetic energy is absorbed and structural integrity is maintained, but the manufacturing process becomes more complex
Solution Approach 1:
The outer casing is pre-formed using braiding techniques before being integrated with the foam core and reinforcing fibers. This preliminary preparation of components allows for more efficient assembly and integration into the final structural element, reducing manufacturing complexity compared to creating the entire structure in one process.
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 solution effectively absorbs and dissipates kinetic energy, preventing structural breakup and maintaining integrity during impacts, thereby reducing the risk of partial or complete detachment of aircraft components and minimizing the risk of chain reactions.
Implementation Method 1
a foam core, contained inside the outer casing and able to fill said outer casing at least partially, said foam core being able at least partially to absorb the kinetic energy generated by the impact
Implementation Method 2
reinforcing elements comprising at least one preform made of dry composite fibers which is incorporated into the foam core in order, in association with the foam core, to dissipate the kinetic energy generated by the impact
Data Source
AI summary
A device for absorbing kinetic energy for an aircraft structural element undergoing a dynamic impact. The device includes an outer enclosure made from a braided composite material configured to preserve its integrity after an impact, and a foam core contained in the outer enclosure and to at least partially fill the outer enclosure. The foam core configured to at least partially absorb the kinetic energy generated by the impact. Reinforcing elements include at least one dry composite fiber preform integrated into the foam core to dissipate, in combination with the foam core, the kinetic energy generated by the impact. A method for integrating the device for absorbing kinetic energy.