Carbon Fiber Space Frame Aircraft Wing Structure
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Solution Overview
Problem
Traditional aircraft wing support structures using metal parts are heavy and costly, requiring complex autoclave assemblies, and do not efficiently distribute loads during flight and landing operations.
Innovation Solution
Aircraft wings are supported by a space frame constructed from carbon fiber rods, with spanwise and chordwise arrays secured by connectors, eliminating the need for heavy metal wing box joints and allowing for a more efficient load distribution and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal wing box joints are used, then structural strength is achieved, but weight increases significantly
Solution Approach 1:
The patent replaces traditional metal wing box joints with a space frame constructed from carbon fiber rods. Carbon fiber composite materials provide equivalent or superior structural strength while significantly reducing weight compared to metal structures, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The wing structure is divided into discrete carbon fiber rod elements arranged in a space frame configuration. This segmentation allows for optimized load distribution through individual rod elements while maintaining overall structural integrity, achieving strength reduction in weight.
2Strength
If heavily reinforced metal structures are used for wing box joints, then structural strength is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Carbon fiber rods can be manufactured and assembled more simply than heavily reinforced metal structures. The composite material properties allow for direct formation of the desired structural shape without complex machining or assembly procedures, reducing manufacturing complexity while maintaining strength.
3Strength
If traditional metal structures are used, then structural support is achieved, but weight penalties occur
Solution Approach 1:
The patent employs carbon fiber composite materials throughout the space frame structure, replacing metal components. These composite materials provide high strength-to-weight ratio, delivering necessary structural support while eliminating the weight penalties associated with traditional metal structures.
4Manufacturing precision
If autoclave assemblies are used for manufacturing, then structural quality is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The carbon fiber rod space frame construction method may allow for alternative manufacturing approaches that reduce or eliminate the need for massive autoclave assemblies. The modular nature of the carbon fiber rod system enables simplified manufacturing processes while maintaining structural quality.
Data Source
AI summary
Aircraft wings have an interior volume that incorporates a space frame as a primary supporting structure of the wing, and enables securement of an aircraft fuselage to the wing. The space frame includes carbon fiber rods arranged to handle tensile and compression loads otherwise carried by conventional wing spars, ribs, and stringers normally connected to heavy structural metal wing box joints at the sides of a fuselage for attachment of left and right wings. The space frame also includes sleeve and shaft connectors secured to the carbon fiber rods, the connectors arranged in truss-like configurations for preventing buckling of the carbon fiber rods. The space frame is designed to extend at least midspan between wings, so that traditional wing box joints on a fuselage can be eliminated. Finally, wing skin panels secured to the space frame are designed to support only aerodynamic loads of flight.