Composite Trailing Edge Profile for Stiffness Without Added Thickness
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Solution Overview
Problem
The existing multi-spar torsion box trailing edge structures face challenges in achieving adequate stiffness without increasing thickness, as monolithic panels are prone to buckling and deformation, and the use of a sandwich structure is not feasible, leading to material and weight inefficiencies.
Innovation Solution
The integration of an elongated profile with a web and flange portions along the spanwise direction of the trailing edge, which provides additional stiffness without thickness increase, allowing for the use of a one-shot manufacturing process and enabling easy replacement of seals without disassembling the profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of monolithic trailing edge panels is increased to guarantee appropriate stiffness, then the structural stiffness is improved, but the weight and material cost increase significantly
Solution Approach 1:
The patent applies composite materials by integrating a metallic profile (aluminum alloy or steel) with the composite panel structure. This hybrid approach combines the stiffness of metal with the lightweight properties of composite materials, achieving adequate structural stiffness without significantly increasing the overall weight compared to using thick monolithic composite panels
Solution Approach 2:
Instead of increasing thickness in the chordwise direction, the patent adds stiffness by introducing an elongated profile element that extends along the spanwise direction. This dimensional shift from thickness increase to spanwise reinforcement provides the necessary structural rigidity while maintaining thin panel geometry and minimizing weight penalty
2Strength
If a sandwich structure is used to reinforce conventional trailing edge panels, then the structural stiffness is improved, but the device complexity and manufacturing complexity increase
Solution Approach 1:
The patent segments the reinforcement function from the panel structure itself by using a separate elongated profile element. This allows the profile to be independently manufactured and then integrated into the trailing edge assembly, simplifying both the panel design and the overall manufacturing process compared to creating complex sandwich structures
Solution Approach 2:
The elongated profile serves multiple functions: it reinforces the panel structurally, provides a mounting structure for seals, and can accommodate access panels. This multi-functionality reduces the need for additional separate components, thereby reducing overall device complexity despite the added reinforcement
3Ease of manufacture
If the trailing edge is manufactured as a monolithic integrated structure, then the manufacturing process is simplified, but the panel stiffness deteriorates due to inability to use sandwich structure reinforcement
Solution Approach 1:
The elongated profile is designed to be installed during the one-shot manufacturing process of the trailing edge. By preparing the profile and its integration points in advance as part of the manufacturing plan, the structure achieves enhanced stiffness without requiring complex post-assembly operations or compromising the simplicity of the integrated manufacturing approach
Solution Approach 2:
The elongated profile acts as an intermediary element that bridges the gap between the monolithic manufacturing approach and the need for reinforcement. It can be integrated during the one-shot process or added as a separate component that works with the monolithic structure, providing stiffness enhancement while preserving manufacturing simplicity
4Ease of manufacture
If C-shape or L-shape fiber ply patterns are used in the last cell of the trailing edge, then the manufacturing process is simplified, but the trailing edge becomes oversized increasing material cost and weight
Solution Approach 1:
Instead of using oversized C-shape or L-shape fiber ply patterns throughout the entire trailing edge structure, the patent applies localized reinforcement only where needed through the elongated profile. This targeted approach provides necessary stiffness in critical areas while avoiding unnecessary material usage in less stressed regions, reducing overall material consumption and cost
Data Source
AI summary
A trailing edge for a composite lifting surface is disclosed having a spar, an upper panel and a lower panel each having a free edge, a seal, and an elongated profile located on the panels following a spanwise direction of the trailing edge. An elongated profile including a web extending along the spanwise direction of the trailing edge, and having first and second flange portions, and a transition zone in between the first and second flange portions extending at different heights with respect to each other. The first flange portion is configured to hold at least a part of the seal underneath, and the second flange portion is configured to contact the panel so that the first flange portion secures the seal to the panel, and the second flange portion secures the elongated profile to the panel.