Composite Panel Thickness Control Plies for Joint Alignment
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Solution Overview
Problem
The manufacturing of laminar composite panels for aircraft wing structures faces challenges in accurately controlling panel thickness, leading to potential gaps or clashes at joints, which induces stress and requires thicker, heavier panels to manage alignment and attachment issues.
Innovation Solution
A method involving the formation of a panel assembly by bonding a stack of thickness control plies to the laminar composite panel, with a ramped section that decreases in thickness towards the edges, allowing for precise thickness control and attachment to components, thereby minimizing stress and alignment issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of laminar composite panels is increased to manage alignment and attachment issues, then the reliability of joint attachment is improved, but the weight of the structure increases
Solution Approach 1:
The patent applies preliminary action by bonding thickness control plies to the inner mould line surface of the laminar composite panel before final assembly. This pre-positioning of thickness control elements ensures that the panel achieves the correct thickness and alignment characteristics prior to attachment, eliminating the need for post-manufacturing adjustments and preventing gaps or clashes at joints without requiring excessive panel thickness
Solution Approach 2:
The patent applies local quality by placing thickness control plies specifically at the inner mould line surface where thickness variation most affects joint alignment, rather than uniformly increasing panel thickness throughout. This localized approach addresses the specific alignment problem at the joint interface while minimizing unnecessary weight addition to the entire panel structure
2Strength
If the thickness of laminar composite panels is increased to cope with stress from bending, then the strength of the panel is improved, but the weight of the structure increases
Solution Approach 1:
The thickness control plies are bonded in advance to compensate for thickness variation, allowing the panel to be manufactured at optimal thickness without requiring excessive thickness to accommodate potential alignment issues or stress requirements. This preliminary compensation enables the use of thinner, lighter panels that still achieve the required strength and alignment performance
3Ease of manufacture
If the thickness of laminar composite panels is not accurately controlled, then the ease of manufacture is improved, but the manufacturing precision of panel thickness deteriorates
Solution Approach 1:
The patent segments the panel thickness control function into two parts: the base laminar composite panel and the separate thickness control plies bonded to its inner mould line surface. This segmentation allows the main panel to be manufactured using standard processes without stringent thickness control, while the thickness control plies provide the necessary precision adjustment at the joint interface, thus maintaining ease of manufacture while achieving high thickness precision
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 approach enables accurate thickness control, reducing the need for significant bending and stress in the panels, allowing for thinner, lighter construction while ensuring precise alignment and attachment, thus improving manufacturing efficiency and reducing assembly complexity.
Implementation Method 1
bonding a stack of thickness control plies of composite material to a laminar composite panel
Data Source
AI summary
A method of manufacturing a structure, the method comprising: forming a panel assembly by bonding a stack of thickness control plies of composite material to a laminar composite panel, the stack of thickness control plies having a first edge proximate an edge of the laminar composite panel, a second edge opposite the first edge, and a ramp where the thickness of the stack of thickness control plies decreases towards the first or second edge; measuring the thickness of the laminate composite panel or the panel assembly; controlling the number of thickness control plies in accordance with the measured thickness; attaching a first component to the panel assembly, the first component having a surface which engages the laminar composite panel and a ramp which engages the ramp in the stack of thickness control plies; and attaching the laminar composite panel at or near its edge to a further component.