Segmented Composite Airfoil Assembly for Embedded Electronics
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Solution Overview
Problem
Existing airfoils for aircraft are often complex and costly to manufacture, particularly when made from composite materials, and may suffer from signal interference issues when housing electric devices due to metal and conductive materials.
Innovation Solution
A lightweight, structurally robust airfoil system constructed from non-metallic and dielectric materials, featuring a segmented clamshell-like configuration without traditional fasteners, with internal supports and segment mounts that provide interlocking connections to secure airfoil segments together, and an embedded electric device protected by a shield to reduce interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metal fasteners and conductive materials are used to construct airfoils, then structural strength and electrical conductivity are improved, but signal interference increases and manufacturing complexity increases
Solution Approach 1:
The airfoil is divided into multiple segments that can be assembled together using interlocking features (receptacles and keys) without traditional fasteners. This segmentation allows for simplified manufacturing of individual segments while maintaining overall structural integrity, and reduces signal interference by eliminating metal fasteners across segment joints.
Solution Approach 2:
The patent combines multiple functions into integrated components: the receptacle and key structures serve both structural connection and alignment functions; the airfoil segments integrate skin, internal supports, and mounting features into unified components. This merging reduces the number of separate parts and assembly steps, lowering manufacturing complexity.
2Weight of moving object
If composite materials are used to construct airfoils, then weight is reduced and signal interference is minimized, but manufacturing cost and complexity increase
Solution Approach 1:
Dividing the airfoil into segments enables each segment to be manufactured separately using composite materials, allowing for optimized tooling and production processes. The segments are then joined using simple interlocking features that don't require complex composite bonding procedures at joints, thereby maintaining manufacturing ease while achieving weight reduction.
Solution Approach 2:
The patent employs disposable or replaceable segment designs where individual airfoil segments can be manufactured as separate units. This approach allows for simpler, potentially less expensive manufacturing processes for each segment while maintaining overall airfoil performance through the composite construction of the segments themselves.
3Strength
If airfoils are constructed as monolithic structures, then structural integrity is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The airfoil is segmented into multiple sections that connect through interlocking receptacles and keys with bonded joints. This segmentation allows each section to be manufactured separately with simplified tooling and processes, while the interlocking design with adhesive bonding maintains structural integrity comparable to or exceeding traditional monolithic construction.
Solution Approach 2:
The patent utilizes composite materials for the airfoil segments and bonding adhesives to create strong joints between segments. The composite construction of segments combined with adhesive bonding at joints provides structural integrity while enabling easier manufacturing of individual segments compared to producing a single large monolithic structure.
4Adaptability or versatility
If electric devices are embedded within airfoils, then functionality is improved, but signal interference from metal and conductive materials increases
Solution Approach 1:
The segmented airfoil structure allows electric devices to be embedded within non-conductive composite material segments, isolating them from metal fasteners and conductive paths that would cause signal interference. The segment boundaries created by the interlocking design provide natural shielding zones for embedded electronics.
Solution Approach 2:
The patent removes traditional metal fasteners and conductive connection elements from the airfoil structure, extracting the harmful conductive materials that would interfere with electric devices. The connection between segments is achieved through non-conductive adhesive bonding, eliminating the source of signal interference while maintaining structural connectivity.
Data Source
Figure 1
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Figure 3~4B
AI summary
An airfoil system (24) is provided that includes an airfoil (26). This airfoil (26) includes a first exterior surface (54A), a second exterior surface (54B), a first airfoil segment (34A) and a second airfoil segment (34B). The airfoil (26) extends widthwise between the first exterior surface (54A) and the second exterior surface (54B). The first airfoil segment (34A) includes a first composite material and a receptacle (102). A base of the receptacle (102) is embedded within the first composite material. The second airfoil segment (34B) includes a second composite material and a key (106). A base of the key (106) is embedded within the second composite material. The key (106) is mated with the receptacle (102) thereby attaching the second airfoil segment (34B) to the first airfoil segment (34A).