Composite Ramp with Triangular Prism Transition
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Solution Overview
Problem
Aircraft structures with wedges require gradients greater than those permissible for Automatic Tape Lay-Up (ATL) machines, leading to design compromises that result in increased weight and manufacturing difficulties, such as conflicts with T-shaped stiffening members and challenges in fitting machined panels on inclined surfaces.
Innovation Solution
A lay-up structure for composite material parts with a wedge between two zones, featuring a first section with an inclined outer surface gradient of 20-50% and a triangular prism with a gradient of less than 20% transitioning to a second section, allowing for manufacturing using ATL machines without weight increases or additional elements, with the triangular prism being cured in the same cycle as the part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the wedge gradient is increased to meet design requirements, then the aerodynamic performance and structural efficiency are improved, but the manufacturing capability using ATL machines deteriorates
Solution Approach 1:
The wedge is divided into two distinct sections: a first section with a steep gradient (20-50%) for aerodynamic efficiency, and a second section with a gentle gradient (<20%) for manufacturability. This segmentation allows each zone to optimize for its specific function while resolving the contradiction between design requirements and manufacturing constraints.
Solution Approach 2:
Different gradient requirements are applied to different zones of the wedge. The first section near the aerodynamic surface maintains a steep gradient for performance, while the second section transitions to a gentle gradient for ease of manufacture. This local differentiation resolves the contradiction by allowing each region to have optimal properties for its specific purpose.
2Ease of manufacture
If the wedge gradient is reduced to enable ATL manufacturing, then the ease of manufacture is improved, but the weight and structural efficiency deteriorate
Solution Approach 1:
The wedge is segmented into two gradient zones, allowing the first section to maintain the steep gradient necessary for weight optimization while the second section uses a gentle gradient for manufacturability. This prevents the need to reduce the entire wedge gradient, thus avoiding weight penalties.
Solution Approach 2:
The steep gradient is preserved locally in the first section where it is most critical for weight efficiency, while only the less critical second section uses the gentler gradient for manufacturing. This localized approach maintains overall structural efficiency while enabling ATL manufacturing.
3Shape
If the wedge gradient is increased for design performance, then the structural efficiency is improved, but the manufacturing complexity and additional elements required increase
Solution Approach 1:
Dividing the wedge into two gradient sections eliminates the need for additional support members or complex manufacturing fixtures. The gentle second section can be manufactured directly with ATL machines, simplifying the overall manufacturing process while maintaining the performance-critical steep first section.
Solution Approach 2:
The design preserves the steep gradient locally where structural efficiency is most important, while the gentle gradient in the second section reduces manufacturing complexity. This local optimization avoids the need for additional elements or complex manufacturing procedures throughout the entire wedge.
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
Enables the manufacture of composite material parts with steeper gradients than previously possible, reducing weight and manufacturing complexities, while ensuring proper lay-up and surface compatibility for aircraft structures.
Implementation Method 1
whose structure comprises from its outside surface to its inside surface: a first section formed from at least two continuous sheets extending parallel to the outer surface of the part, the outer surface of the wedge including an inclined surface with a gradient between 20% and 50%; a triangular prism placed on the said first section and with its largest surface dimensioned in such a way that it forms a wedge having a gradient of less than 20% ending at the start of the said second zone
Data Source
Figure 1~2
Figure 3a~3b
Figure 4~5a
AI summary
A part (5) of composite material having a wedge(13) between two zones (11, 15), the second zone (15) being shorter than the first zone (11), whose structure comprises from its outer surface (21) to its inner surface (23): a first section (31) formed from at least two continuous sheets (41) extending parallel to its outer surface (21), the gradient of the wedge (13) being between 20% and 50%; a wedge (33) in the shape of a triangular prism with its larger surface (27) dimensioned in such a way that it forms a wedge having a gradient of less than 20%; a second section (35) formed by a plurality of continuous sheets (45) extending parallel to the surface bounded by the said first section (31) with the said wedge (33) placed upon it. The invention also relates to a process for manufacture of the part (5).