Composite Element With Integrated Protrusion Stiffeners
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Solution Overview
Problem
Existing composite elements used in structural applications, such as aircraft components, require time-consuming and defect-prone processes for attaching separate stiffening pieces, which complicates manufacturing and assembly.
Innovation Solution
The composite element integrates local stiffeners as directed protrusions on the skin plates, with additional composite structures inside the protrusions, which are formed during the manufacturing process, eliminating the need for separate stiffening parts and allowing for automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate stiffening pieces are fastened to composite elements, then rigidity is improved, but manufacturing time increases and defect risk increases
Solution Approach 1:
The patent merges the stiffening function directly into the composite element by forming protrusions that integrate stiffening pieces with the skin plate. This eliminates separate fastening operations, reducing manufacturing time while maintaining rigidity improvement. The protrusions are formed during the composite manufacturing process itself, combining multiple functions into a single integrated structure.
Solution Approach 2:
The stiffening protrusions are formed preliminarily during the composite element manufacturing process, before final assembly. By pre-forming the protrusions with integrated stiffening structures, the patent eliminates subsequent fastening steps, thereby reducing overall manufacturing time and preventing defects associated with separate fastening operations.
2Strength
If separate stiffening pieces are fastened to composite elements, then rigidity is improved, but the fastening process becomes vulnerable to defects
Solution Approach 1:
The patent combines the stiffening function with the skin plate by forming protrusions that integrate both components. This merging eliminates adhesive bonding or mechanical fastening interfaces, which are common sources of defects. The integrated structure ensures reliable rigidity improvement without introducing fastening-related vulnerability.
3Strength
If additional composite structures are added to protrusions, then rigidity is enhanced, but manufacturing complexity increases
Solution Approach 1:
The patent merges additional composite structures directly into the protrusions during the same manufacturing process. By forming both the protrusion and additional composite structures in one integrated operation, the patent enhances rigidity without significantly increasing manufacturing complexity. The structures are formed simultaneously rather than as separate assembly steps.
Solution Approach 2:
The patent uses composite materials for both the skin plate and the additional structures within protrusions. This allows both components to be manufactured using the same composite laying and curing process, enhancing rigidity while maintaining manufacturing simplicity through process integration rather than material or process differentiation.
4Productivity
If integrated stiffening protrusions are formed during manufacturing, then assembly efficiency is improved, but manufacturing process complexity increases
Solution Approach 1:
The patent merges the stiffening structure formation into the basic composite manufacturing process. By forming protrusions with integrated stiffening capabilities during the same laying and curing operations, the patent improves assembly efficiency (eliminating separate stiffener installation) while keeping process complexity manageable through integration rather than addition of separate manufacturing steps.
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 solution reduces manufacturing time, minimizes defects, and enhances the rigidity and durability of the composite element by integrating stiffeners within the structure, while also potentially reducing weight and improving assembly efficiency.
Implementation Method 1
the additional first composite structures may be laminated on the inner surface of the first skin plate at the designed positions of the protrusions to be formed
Implementation Method 2
the basic composite structure of the first skin plate and the first additional composite structure attached on an inner surface of the first skin plate are being bulged together for forming the several stiffened protrusions
Data Source
AI summary
A composite element and a method of manufacturing the same. The composite element comprises a first skin plate and second skin plate, which are manufactured as separate pieces and are assembled in a separate phase. At least the first skin plate comprises several protrusions on an outer surface of the plate. The protrusions serve as local stiffeners and are further stiffened by means of one or more additional composite structures arranged inside the protrusions.