Integrated Load Introduction Fin in Composite Flow Body
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Solution Overview
Problem
The use of metallic load introduction elements in aircraft flow bodies made from fiber composite materials is costly due to the need for individual manufacturing and complex assembly, which increases production costs and weight.
Innovation Solution
A flow body design incorporating a load introduction fin as an integral component with the spar, made from lightweight fiber composite materials, which reduces additional weight and production costs by integrating the load introduction fin with the spar and external skin, allowing for effective force transmission and reduced mechanical strength requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metallic load introduction elements are used in fiber composite flow bodies, then structural strength and load bearing capacity are ensured, but weight increases and production costs increase due to individual manufacturing and complex assembly
Solution Approach 1:
The load introduction fin is merged with the spar as a single integral component made from fiber composite materials. This integration eliminates the need for separate metallic load introduction elements and their associated mounting hardware, thereby reducing weight while maintaining structural strength through the unified composite construction.
Solution Approach 2:
The spar and load introduction fin are constructed from fiber composite materials that provide sufficient strength and stiffness to bear aerodynamic and inertial loads. The composite material properties allow the integrated structure to achieve the required mechanical performance without relying on heavy metallic components.
2Strength
If metallic load introduction elements are used in fiber composite flow bodies, then structural strength and load bearing capacity are ensured, but production costs increase due to individual manufacturing and complex assembly
Solution Approach 1:
By combining the spar and load introduction fin into a single molded component, the number of manufacturing steps is reduced. The integrated design eliminates separate production processes for metallic elements and their mounting, simplifying manufacturing and reducing assembly complexity while maintaining structural integrity.
Solution Approach 2:
The use of fiber composite materials allows for cost-effective manufacturing through processes such as mold injection or layer-by-layer construction. This approach replaces expensive metallic components and their associated fastening systems, reducing production costs while achieving the required load bearing capacity through optimized composite material placement.
3Force
If separate load introduction fins are used, then force transmission is achieved, but additional weight and mechanical strength requirements increase
Solution Approach 1:
The load introduction fin is integrated into the spar structure, eliminating the need for separate components. The unified design maintains effective force transmission from the aerodynamic surfaces through the composite structure, while removing the additional weight that would result from separate metallic fins and their mounting hardware.
Data Source
AI summary
A flow body for an aircraft with a leading edge and a trailing edge includes a first spar, a second spar, and an external skin that spans from the leading edge to the trailing edge and on both sides rests on the spars. At least one of the first spar and the second spar includes a web and two spaced-apart flanges that enclose the web, on which flanges the skin that spans the respective spar is arranged. At least one of the first spar and the second spar includes at least one load introduction fin that forms an integral component with the web and extends outwards by way of one of the flanges and the skin that rests on the spars.