Composite Wing Joint With Stair-Step Metal Layer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Composite joints in aircraft made from composite materials often require thicker structures to handle higher loads, leading to increased weight and reduced performance due to the need for larger fasteners, which can be impractical and heavy, especially when metal is used to meet thickness requirements, potentially precluding the use of composite materials in other areas.
Innovation Solution
A composite wing structure featuring multiple layers of composite material with a metal layer bonded between them, where the metal layer transitions from a thicker first thickness at the fastener area to a thinner second thickness in a stair-step shape, allowing for efficient load transfer and reduced weight, while maintaining structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the thickness of composite material at the joint is increased to handle higher loads, then the joint strength is improved, but the overall weight of the aircraft increases
Solution Approach 1:
The patent applies local quality by varying the thickness of the metal layer only at the joint area where fasteners are located, while keeping the skin panel thickness uniform in non-joint areas. The metal layer has a first thickness at the joint to handle higher loads and a second, smaller thickness in non-joint areas, allowing the structure to be strong where needed without adding unnecessary weight throughout the entire panel.
Solution Approach 2:
The patent segments the metal layer into different thickness zones: a first thickness region at the joint area and a second thickness region in non-joint areas. This segmentation allows the structure to optimize material distribution, providing enhanced strength only where fasteners are located while reducing weight in areas where full thickness is not required.
2Strength
If the thickness of composite material at the joint is increased to accommodate larger fasteners, then the joint load capacity is improved, but the manufacturing complexity increases
Solution Approach 1:
The metal layer is designed with local quality variations, having a first thickness at the joint area to accommodate fasteners and a second, reduced thickness in non-joint areas. This localized thickness variation simplifies manufacturing compared to increasing the entire panel thickness, as it allows standard panel fabrication followed by selective metal layer application or integration only where structurally necessary.
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 configuration enables the composite wing to carry higher loads with a reduced weight, as the metal layer supports the composite material effectively, allowing for lighter aircraft construction without compromising performance, and facilitates easier manufacturing by allowing for a gradual thickness reduction.
Implementation Method 1
the metal layer changes in thickness by changing from the first thickness to the second thickness with a stair-step shape
Data Source
Figure 1~2
Figure 3
Figure 4
AI summary
A method and apparatus comprises a first number of layers of a composite material for a wing, a second number of layers of the composite material for the wing, and a metal layer located between the first number of layers and the second number of layers in the wing. The metal layer has a first thickness at a first area configured to receive a number of fasteners and a second thickness at a second area.