Composite Torque Box Sleeve for Aircraft Wing Assembly
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Solution Overview
Problem
Conventional aircraft torque box structures are complex to assemble, heavy due to metal materials and fasteners, and prone to joint failures due to spanwise joints, which compromise structural integrity and increase weight.
Innovation Solution
A wing assembly with a torque box sleeve having integral sides forming a continuous surface and an internal support subassembly coupled to the sleeve, formed from composite materials with rounded corners and reduced fasteners, allowing for a lighter, more efficient structural design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional torque box structures use metal materials and multiple fasteners to ensure structural strength, then the structure achieves sufficient strength, but the weight increases significantly
Solution Approach 1:
The patent applies composite materials (fiberglass or carbon fiber reinforced plastic) to replace traditional metal materials in the torque box structure. The composite torque box sleeve maintains structural strength while significantly reducing weight, achieving a strength-to-weight ratio superior to conventional metal constructions.
Solution Approach 2:
The patent merges multiple discrete components (spars, skins, stringers, ribs) into an integrated composite torque box sleeve structure. This monolithic composite structure eliminates the need for numerous fasteners and joints, reducing weight while maintaining structural integrity through the inherent properties of composite materials.
2Strength
If conventional torque box structures include multiple internal support members and stringers to provide structural support, then the structural integrity is maintained, but the assembly complexity increases and requires very tight tolerances
Solution Approach 1:
The patent integrates multiple support functions into the composite torque box sleeve itself, which provides structural support through its monolithic construction. The composite structure inherently provides the support function that would otherwise require multiple separate metal members, stringers, and fasteners, thereby simplifying the assembly process and reducing tolerance requirements.
Solution Approach 2:
The patent segments the internal support structure into a separate pre-fabricated subassembly that is inserted into the composite torque box sleeve. This allows the support structure to be manufactured independently with precise tolerances controlled during subassembly fabrication, then installed as a unit, reducing overall assembly complexity.
3Strength
If conventional torque box structures include stringers and internal support members to maintain skin shape and provide stiffness, then the structural support is adequate, but the space available for fuel and internal systems is reduced
Solution Approach 1:
The patent combines the structural support function with the skin structure itself through the composite torque box sleeve design. The composite material and laminate construction provide inherent stiffness and shape maintenance capabilities, eliminating the need for additional internal support members and stringers that would consume internal volume, thereby maximizing space for fuel and systems.
4Reliability
If conventional torque box structures use thousands of fasteners to join metal components, then the structural connections are secure, but the assembly time increases and the risk of joint failure increases
Solution Approach 1:
The patent uses composite materials to create a monolithic torque box sleeve structure that eliminates the need for thousands of fasteners. The composite construction provides inherent structural continuity and eliminates joint interfaces, thereby eliminating the assembly time associated with installing and inspecting numerous fasteners while also eliminating the risk of joint failure.
Data Source
AI summary
A wing assembly for an aircraft includes a torque box sleeve having an open end and a plurality of integral sides including leading, aft, top and bottom sides that jointlessly form a continuous surface having a generally airfoil shape. The wing assembly includes an internal support subassembly having a plurality of ribs coupled to a central spar. The internal support subassembly is formed into a single component outside the torque box sleeve and inserted into the open end of the torque box sleeve as the single component. The internal support subassembly is coupled to an interior of the torque box sleeve.