Composite ALFC Panel With Integrated Plenums for Drag Reduction
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Solution Overview
Problem
Existing active laminar flow control (ALFC) systems for aircraft are difficult to commercially implement due to various deficiencies, necessitating an improved system and manufacturing method for promoting laminar flow over aerodynamic surfaces.
Innovation Solution
The development of a fiber-reinforced composite panel with a radial outer skin, radial inner skin, and corrugated core forming plenums, which are fluidly coupled with perforations, and a suction system, allowing for the co-curing of the panel as a monolithic body during a single curing cycle, reducing weight and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional ALFC systems are implemented, then laminar flow control is achieved, but system complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the plenum chamber, suction device, and outer skin into an integrated composite panel structure. The plenum chamber is formed by bonding corrugated panels to the outer skin, creating a unified structure that eliminates separate components and reduces overall system complexity while maintaining laminar flow control functionality.
Solution Approach 2:
The patent employs fiber-reinforced composite materials for the panel structure, combining different material properties to achieve both structural integrity and aerodynamic functionality. The composite construction allows the panel to serve multiple purposes: structural support, plenum chamber formation, and suction device integration.
2Reliability
If multiple separate components are used for ALFC system, then functionality is achieved, but manufacturing time and cycles increase
Solution Approach 1:
The patent combines multiple functional components (outer skin, plenum chamber, suction device) into a single integrated panel that can be manufactured in one production cycle. The corrugated panels are bonded directly to the outer skin to form the plenum chamber, and suction devices are integrated into the panel structure, eliminating the need for separate assembly steps.
Solution Approach 2:
The plenum chamber and suction device structures are pre-formed as integral parts of the panel during manufacturing, rather than being added as separate components after assembly. This preliminary integration of functional elements into the panel structure during initial production reduces subsequent assembly time and manufacturing cycles.
3Ease of manufacture
If conventional materials are used for panel construction, then ease of manufacture is maintained, but weight increases
Solution Approach 1:
The patent specifies the use of fiber-reinforced composite materials for constructing the panel, outer skin, and plenum chamber structures. These composite materials provide high strength-to-weight ratio, reducing the overall panel weight compared to conventional materials while maintaining structural integrity and ease of manufacturing through standardized composite fabrication processes.
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
This solution effectively promotes laminar flow by removing boundary layer air, reducing drag, and decreasing the overall weight of the aircraft propulsion system while maintaining structural reinforcement, thus improving the commercial viability of ALFC systems.
Implementation Method 1
The plenum duct is also fluidly coupled with a suction device, which draws air into the plenum duct through the perforations in the outer surface
Implementation Method 2
This modification generally removes low energy air from a boundary layer along an extent of the outer surface to prevent that boundary layer from thickening and eventually tripping into a turbulent flow
Implementation Method 3
laminar flow over an aerodynamic surface, such as an outer surface of a nacelle of an aircraft propulsion system, reduces drag compared to turbulent flow over the same surface
Data Source
AI summary
An assembly is provided for active laminar flow control. This assembly includes a panel, which panel includes an outer skin, an inner skin and a plurality of plenums between the outer skin and the inner skin. Each of the plurality of plenums is fluidly coupled with a respective array of perforations through the outer skin. The panel is constructed from fiber-reinforced composite material.