Composite Load Introducing Element for Aircraft Control Surfaces
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Solution Overview
Problem
The production of metal load introducing ribs for control surfaces in aircraft is costly and results in mechanical stresses due to differing heat expansion behaviors between metal ribs and fiber-reinforced composite materials.
Innovation Solution
A load introducing element composed of two fibrous components that are jointly infiltrated and cured, forming an integral module with uniform material properties and optimized fiber orientations, reducing weight and heat expansion mismatches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal load introducing ribs are used, then structural strength is ensured, but production costs increase and heat expansion mismatches occur
Solution Approach 1:
The patent applies composite materials by replacing traditional metal load introducing ribs with components made from fiber-reinforced plastics. The load introducing element consists of a rib made of fiber-reinforced plastic material that integrates both structural and load-introducing functions. This composite material approach reduces production costs while maintaining structural strength and eliminates heat expansion mismatches with the control surface.
2Force
If metal load introducing ribs are used, then load introduction is achieved, but mechanical stresses occur due to heat expansion differences
Solution Approach 1:
The patent applies homogeneity by using the same material type (fiber-reinforced plastic) for both the control surface and the load introducing rib. This ensures matching thermal expansion coefficients and eliminates mechanical stresses caused by heat expansion differences. The rib and control surface are made from compatible composite materials that expand and contract uniformly with temperature changes.
3Stability of the object's composition
If metal ribs are machined from solid workpiece, then structural integrity is maintained, but production complexity and cost increase
Solution Approach 1:
The patent applies parameter changes by transitioning from metal material parameters to composite material parameters. The load introducing element is manufactured using composite materials with different structural characteristics - layers of fibrous preforms infiltrated with resin - allowing for simplified production processes while maintaining structural integrity. The composite structure achieves strength through fiber orientation and layering rather than solid metal machining.
4Weight of moving object
If fiber reinforced composite materials are used for control surface, then weight is reduced, but heat expansion mismatches with metal ribs occur
Solution Approach 1:
The patent applies homogeneity by matching the material composition of the rib with the control surface. Both components are made from fiber-reinforced plastic materials with compatible thermal properties. This ensures uniform heat expansion behavior across the entire control surface assembly, eliminating the thermal mismatch problems that would occur with metal ribs attached to composite surfaces.
Data Source
AI summary
A method for producing a load introducing element for a control surface of an aircraft or a spacecraft, includes cutting to size preformed fibrous substructures out of a fibrous material. The method also includes draping the fibrous substructures to mold at least one first component, at least one second component and at least one first flange in the form of a single semi-finished product. Further, the method includes inserting the semi-finished product into a mold, injecting matrix material, and curing the semi-finished product to form a finished product.