Composite Trailing Edge with Pressurizable Members

Solution Overview

Problem

Conventional methods for manufacturing leading and trailing edge structures in aerospace vehicles result in suboptimal aerodynamic shapes due to assembly and processing limitations, leading to increased weight, drag, and limited taper angles, which hinder both structural robustness and aerodynamic performance.

Innovation Solution

The use of pressurizable members and counteracting pressures to embed cored members between fiber plies during the manufacturing process, allowing for the creation of complex-shaped, three-dimensional composite structures with reduced weight and increased stiffness, enabling more tapered designs that enhance aerodynamic performance and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If conventional assembly and processing methods are used to manufacture leading and trailing edge structures, then structural robustness is maintained, but aerodynamic shape quality deteriorates due to assembly limitations and processing constraints

Engineering Contradiction:

Improveaerodynamic shape qualityVSAvoidmanufacturing complexity

Core Design Contradiction:

ShapeVSEase of manufacture

Solution Approach 1:

The patent merges the trailing edge structure into the main wing box structure, eliminating separate assembly operations. The trailing edge is formed as an integral part of the wing box during the same manufacturing process, achieving complex aerodynamic shapes without additional assembly steps or tooling requirements.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent incorporates trailing edge formation into the preliminary wing box manufacturing process. By preparing and forming the trailing edge structure during the initial autoclave cycle rather than as a subsequent assembly step, the method achieves high-quality aerodynamic shapes while simplifying the overall manufacturing workflow.

Inventive Principle:

Principle #10Preliminary action

2Weight of moving object

If conventional trailing edge structures are used, then manufacturing simplicity is maintained, but weight increases and aerodynamic efficiency decreases

Engineering Contradiction:

Improvetrailing edge weightVSAvoidmanufacturing efficiency

Core Design Contradiction:

Weight of moving objectVSProductivity

Solution Approach 1:

The patent changes the manufacturing parameters by using a single autoclave cycle with integrated tooling to form both the wing box and trailing edge simultaneously. This approach reduces the number of manufacturing steps, decreases total production time, and lowers weight compared to conventional multi-step assembly methods.

Inventive Principle:

Principle #35Parameter changes

3Strength

If tapered designs are implemented to improve aerodynamic performance, then drag reduces and lift increases, but structural robustness deteriorates due to limited taper angles in conventional designs

Engineering Contradiction:

Improvestructural robustnessVSAvoidtaper angle

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The patent merges the trailing edge structure into the main wing box structure, eliminating separate assembly operations. The trailing edge is formed as an integral part of the wing box during the same manufacturing process, achieving complex aerodynamic shapes without additional assembly steps or tooling requirements.

Inventive Principle:

Principle #5Merging (Combining)

4Productivity

If complex-shaped three-dimensional composite structures are manufactured using conventional methods, then structural integrity is maintained, but manufacturing time increases and assembly complexity increases

Engineering Contradiction:

Improvemanufacturing cycle timeVSAvoidassembly complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent merges the trailing edge structure into the main wing box structure, eliminating separate assembly operations. The trailing edge is formed as an integral part of the wing box during the same manufacturing process, achieving complex aerodynamic shapes without additional assembly steps or tooling requirements.

Inventive Principle:

Principle #5Merging (Combining)

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 the production of lighter, more aerodynamically efficient trailing edge structures with improved load-carrying capabilities, lightning strike resistance, easier manufacturing, and reduced assembly time, while minimizing weight and drag, thereby enhancing lift and reducing flutter issues.

Implementation Method 1

pressurizing an outer surface of the pre-cured assembly with a first pressure; and pressurizing the inner surface of at least some of the pressurizable members with a second pressure, wherein the first pressure and the second pressure operate to compress the fiber plies between the pressurizable members and tool to form the trailing edge structure

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS10173789B2Cellular core composite leading and trailing edges

Publication Date: 2019.01.08 AEROSUD TECH SOLUTIONS PTY LTD

AI summary

A complex-shaped, three-dimensional fiber reinforced composite trailing edge structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers placed onto pressurizable members to form continuous fore and aft loops. In turn, the loops may be structurally functional to transfer loads from the trailing edge structure to a wing center section. The trailing structure may include may include fillers and/or a metallic insert, wherein the metallic insert may provide a lightening strike capability for the trailing edge structure.