Integrated Composite Trailing Edge Manufacturing via Double C-Preforms
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Solution Overview
Problem
The existing manufacturing methods for aircraft trailing edges using composite fiber reinforced polymers are hindered by the weight of rivets and the time-consuming assembly process, which affects weight savings and cost-effectiveness.
Innovation Solution
The method involves forming double C-shaped laminated preforms using prepreg laminates through manual or automatic lay-up followed by hot-forming or press-forming, eliminating the need for rivets and allowing for a single curing step to integrate the trailing edge components, reducing assembly and manufacturing steps while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If separate components are manufactured and assembled using rivets, then structural integrity is achieved, but weight increases and assembly time extends
Solution Approach 1:
The patent merges multiple separate components (upper cover, lower cover, ribs, trailing edge) into a single integrated trailing edge assembly manufactured from one continuous prepreg laminate. This eliminates the need for rivets and mechanical fasteners, directly resolving the contradiction by achieving structural integrity through monolithic construction while eliminating the weight of fastening hardware
Solution Approach 2:
The patent replaces the mechanical riveting system with a chemical bonding system where prepreg laminates are cured to form permanent bonds between components. The resin matrix chemically bonds the fiber reinforcements together, substituting mechanical fasteners with a chemical bonding mechanism that eliminates rivet weight while maintaining structural integrity
2Strength
If separate components are manufactured and assembled using rivets, then structural integrity is achieved, but assembly time increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated process where the trailing edge assembly is manufactured as one piece. This eliminates the sequential assembly steps of positioning, riveting, and inspecting separate components, directly reducing assembly time while maintaining structural integrity through the integrated monolithic construction
Solution Approach 2:
The patent performs preliminary forming of the entire trailing edge assembly structure during the single curing process. The prepreg laminates are pre-configured with all structural features (covers, ribs, trailing edge geometry) before curing, eliminating the need for post-assembly operations and reducing total manufacturing time while ensuring structural integrity is built-in from the start
3Device complexity
If multiple components are assembled together, then structural complexity is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent changes the material state parameters of the prepreg laminates through controlled heating and curing processes. The material transitions from a flexible prepreg state (easy to form) to a cured composite state (structurally strong), allowing complex geometries to be manufactured easily by adjusting temperature and time parameters during the single integrated manufacturing process
Solution Approach 2:
The patent utilizes composite material properties where fibrous reinforcements provide structural strength and a resin matrix provides binding and flexibility during forming. This composite nature allows the material to be formed into complex integrated geometries while maintaining the strength required for structural integrity, resolving the contradiction between manufacturing ease and structural complexity
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 reduces weight and assembly time, enhances integration, and lowers costs by eliminating mechanical bonds between ribs and covers, while maintaining structural performance.
Implementation Method 1
forming the double C-shaped laminated preforms and its recesses by for instance a hot-forming or a press-forming process
Implementation Method 2
forming the double C-shaped laminated preforms and its recesses by for instance a hot-forming or a press-forming process
Implementation Method 3
a single curing step to integrate the trailing edge components
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention refers to an integrated composite trailing edge and to its method of manufacturing. The trailing edge comprises: - an integrated main structure comprising: ○ an upper cover (1), ○ lower flanges, and ○ a set of ribs (23) extending between the upper cover (1) and the lower flanges, - a set of sandwich type lower panels (22) attachable to the lower flanges of the integrated main structure. The method comprises the steps of providing a set of prepreg laminated preforms over a set of tool modules (7) having a hollow (9) so that each laminated configures a double C-shaped laminated preform (10) having an upper section (15) with a recess (16), two primary (3) and secondary (8) flanges, the upper section (15) partly forming the upper cover (1), the two primary flanges (3) partly forming the ribs (23) and the two secondary flanges (8) forming the lower flanges.