Integrated Composite Corner Structure for Load Transfer
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Solution Overview
Problem
Conventional torque box construction in aerospace and automotive applications requires separate components joined with mechanical fasteners, leading to inefficiencies in weight optimization and load transfer across curved corners.
Innovation Solution
A composite aerofoil structure with fibre-reinforced plies, featuring a stack with external and internal plies that transition across curved corners, where internal plies are oriented at specific angles to enhance load transfer and reinforcement, forming a single integrated part rather than separate components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate components are joined using mechanical fasteners, then assembly is simplified and manufacturing is easier, but weight increases and load transfer efficiency deteriorates
Solution Approach 1:
The patent merges multiple separate components (skins and spars) into a single integrated composite structure formed by continuous fibre placement. This eliminates the need for mechanical fasteners and component assembly, thereby reducing weight while maintaining manufacturing feasibility through automated fibre placement processes.
Solution Approach 2:
The invention uses composite materials with specifically oriented fibres to create an integrated structure that replaces traditional metal components joined by fasteners. The composite material approach allows for weight reduction while achieving the same structural function through material properties rather than mechanical connections.
2Ease of manufacture
If separate components are joined using mechanical fasteners, then manufacturing process is simpler, but load transfer across corners deteriorates
Solution Approach 1:
By merging separate components into a single integrated composite structure, the invention eliminates weak interfaces where mechanical fasteners would be required. The continuous fibre placement creates seamless load paths across corners, significantly improving load transfer efficiency while maintaining manufacturing simplicity through automated processes.
Solution Approach 2:
The invention applies local quality by orienting fibres in specific directions at corners to optimize load transfer. The fibre placement is tailored locally at corner regions to follow the principal stress trajectories, providing enhanced strength where it is most needed while keeping the overall manufacturing process simple.
3Weight of moving object
If fibres are aligned with component-specific rosettes, then each component is optimized for weight, but load transfer across interfaces deteriorates
Solution Approach 1:
The invention merges the optimization of individual components into a unified optimization of the entire structure. By treating the skin-spar assembly as a single integrated component, the fibre orientation can be optimized for overall structural performance rather than individual component weight, thereby improving load transfer at interfaces while maintaining weight efficiency.
Solution Approach 2:
The invention applies local quality by varying fibre orientation angles at different locations, particularly at corner regions where load transfer is critical. The fibre angles are locally adjusted to match the principal stress directions at each position, optimizing both weight and strength at the interface regions where it matters most.
4Ease of manufacture
If traditional composite layup is used with parallel fibres, then manufacturing is easier, but corner reinforcement and load transfer deteriorate
Solution Approach 1:
The invention applies local quality by changing fibre orientation angles specifically at corner regions rather than using uniform parallel fibres throughout. The fibre placement is locally adapted to follow the curvature and stress patterns at corners, providing enhanced reinforcement where needed while maintaining manufacturing ease through automated fibre placement that can accommodate angle changes.
Solution Approach 2:
The invention introduces dynamics into the fibre placement by varying fibre orientation angles along the length of the structure, particularly at corners. Rather than static parallel fibres, the fibre angles dynamically adjust to match the local stress state, improving corner reinforcement while the automated placement process maintains manufacturing ease.
Data Source
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AI summary
A composite structure comprising a first section (15); a second section (13); and a curved corner (18) joining the first section to the second section. The structure comprises a stack of fibre-reinforced plies (20-30). The stack includes a first external ply (20) which runs from the first section into the second section round an inside of the corner; and a second external ply (21) which runs from the first section into the second section round an outside of the corner (18). A discontinuous first internal ply (28) is sandwiched between the first and second external plies (20,21) and is dropped off inside the structure so that more of the first internal ply (28) is located within the first section (14) than within the second section (13). A second internal ply (22,25,30) is sandwiched between the first and second external plies (20,21). The fibres of the first internal ply (28) run at an angle €¢ to the fibres of the second internal ply (22,25,30). In some embodiments the angle €¢ is greater than 3° but less than 20°. In one embodiment the angle €¢ is between 35° and 42°.