Blended Wing Body Structural Foam with Flange and Web Skin

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Solution Overview

Problem

Non-tubular aircraft fuselages lack the capability to resist pressure loads through hoop tension in the skin panels, which is effectively utilized in tubular fuselages, leading to structural weaknesses under pressurization.

Innovation Solution

The use of a structural foam with a predetermined shape, an outer flange, an inner flange, and a web skin that encapsulates the inner flange and structural foam, transferring pressurization loads to the aircraft's frames, thereby enhancing structural strength and preventing resin introduction during molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If non-tubular fuselage design is used, then manufacturing flexibility and aerodynamic efficiency are improved, but structural strength under pressurization loads deteriorates

Engineering Contradiction:

Improveaerodynamic efficiencyVSAvoidstructural strength

Core Design Contradiction:

Adaptability or versatilityVSStrength

Solution Approach 1:

The patent employs composite construction by combining web skin, flanges, and structural foam to create a hybrid structure that achieves both aerodynamic efficiency and pressurization resistance in non-tubular configurations

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The structure is divided into discrete components (web skin, outer flange, inner flange, structural foam) that can be manufactured separately and assembled, enabling flexible non-tubular geometries while maintaining structural integrity through distributed load paths

Inventive Principle:

Principle #1Segmentation

2Strength

If structural foam is used, then structural strength is improved, but resin infiltration during molding becomes a harmful factor

Engineering Contradiction:

Improvestructural strengthVSAvoidresin infiltration

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The structural foam is positioned and secured within the mold cavity before the resin injection process begins, preventing resin from infiltrating into the foam structure during molding

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The web skin and flanges act as intermediary barriers between the resin and structural foam, physically separating them during the molding process to prevent harmful resin infiltration while maintaining structural integrity

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12187425B1Aircraft component with structural foam

Publication Date: 2025.01.07 JETZERO INC

AI summary

An aircraft component including a structural foam having a predetermined shape, an outer flange located near a first end of the structural foam, an inner flange located near a second end of the structural foam, a web skin encapsulating the inner flange and at least a portion of the structural foam wherein the structural foam is affixed to the web skin, wherein the aircraft component comprises a portion of a blended wing body aircraft (BWB), the BWB having no demarcation between a wing and a main body of the BWB.