Composite Multispar Trailing Edge for Aircraft Lifting Surfaces
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Solution Overview
Problem
The existing aircraft trailing edge structures require complex and costly assembly processes, with multiple parts and fasteners, and struggle to segregate hydraulic and electrical systems effectively, especially in reduced area configurations, leading to increased weight and costs.
Innovation Solution
A multispar cell concept using C-shape composite forms that integrate the trailing edge with the torsion box, eliminating the need for air load ribs and creating auxiliary cells for system segregation, allowing for one-shot manufacturing and reduced assembly operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional trailing edge structures with multiple ribs and fasteners are used, then structural strength is maintained, but assembly complexity and manufacturing cost increase significantly
Solution Approach 1:
The patent merges multiple separate structural elements (ribs, trailing edge, spar attachments) into a single integrated trailing edge component manufactured as one piece. This eliminates the need for multiple fasteners and assembly operations, directly reducing assembly complexity while maintaining structural integrity through the integrated design
Solution Approach 2:
The trailing edge is segmented into functional zones (hydraulic system area, electrical system area, control surface attachment area) within the single integrated structure. This allows different sections to serve specific purposes while maintaining overall structural unity and simplifying the manufacturing process
2Reliability
If hydraulic systems are segregated in reduced area trailing edges, then safety requirements are met, but the trailing edge area must be sufficiently large to accommodate segregation
Solution Approach 1:
The patent uses the vertical dimension (thickness direction) of the trailing edge to segregate hydraulic and electrical systems through dedicated cavities and channels. This allows effective system separation without requiring increased planar area, accommodating safety requirements within the existing trailing edge footprint
3Productivity
If multiple parts are manufactured separately and assembled, then manufacturing flexibility is maintained, but lead time and assembly costs increase
Solution Approach 1:
The trailing edge is designed with pre-integrated features (attachment points, system cavities, reinforcement structures) built into the single-piece manufacturing process. This preliminary integration of functions that would otherwise require separate assembly steps significantly reduces lead time while maintaining manufacturing feasibility through composite molding techniques
Data Source
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AI summary
Trailing edge (2) for a composite multispar integrated lifting surface (1) comprising: - A first C-shape composite form (10) that comprises a web (11) and two flanges (12). The web (11) forming a portion of the rear spar (20) of a torsion box (3). The two flanges (12) extending along the skin (21) chordwise direction. - A second C-shape composite form (15) comprising a web (16) and two flanges (17). The web (16) forming an auxiliary spar (22). The flanges (17) extending along the skin (21) chordwise direction. The first C-shape composite form (10) and the second C-shape composite form (15) forming a first auxiliary cell (30) and a second cell (31). The first auxiliary cell (30) being delimited by the first C-shape composite form (10) and the second C-shape composite form (15). The second cell (31) being an open cell delimited by the second C-shape composite form (15).