Corrugated Composite Wing Rib Design
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Solution Overview
Problem
Existing wing ribs manufactured from lightweight composite materials are cost-prohibitive, and there is a need for lighter and stronger materials that can efficiently transmit loads while maintaining desired flight characteristics.
Innovation Solution
The use of a corrugated composite web with a wave pattern, made from composite materials like carbon fibers within a polymer matrix, which provides compression and tensile strength without the need for additional rib chords, and can be manufactured using large sheets with uniform thickness, simplifying production by eliminating individual rib tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If wing ribs are manufactured from lightweight composite materials, then weight is reduced and strength is improved, but manufacturing cost increases significantly
Solution Approach 1:
The wing rib is divided into two main segments: a corrugated web portion and flange portions. The corrugated web is cut from a large sheet of corrugated composite material, while the flanges are separate pieces that are joined to the web. This segmentation allows the expensive composite material to be used only where structurally necessary (the web), while flanges can use more cost-effective materials or simpler construction methods.
Solution Approach 2:
The corrugated composite web serves multiple functions simultaneously: it provides the primary load-bearing structure, resists compression through its corrugated geometry, provides tensile strength through the composite material, and eliminates the need for additional rib chords. This multi-functionality reduces the total amount of expensive composite material required compared to traditional full-composite rib designs.
2Reliability
If traditional composite materials are used for wing ribs, then structural integrity is maintained, but manufacturing complexity and cost increase
Solution Approach 1:
The web is formed with a corrugated (wave-like) cross-section rather than a flat geometry. This curvature provides structural advantages by increasing moment of inertia and resistance to compression while using less material. The corrugated shape is created by forming a large sheet into a repeating wave pattern, which can then be cut into multiple web pieces for different rib positions.
Solution Approach 2:
The invention changes the geometric parameters of the web by introducing corrugations with specific wave heights, wavelengths, and angles. These parameter changes optimize the structural performance of the web, allowing it to resist compression and bending loads more effectively. The corrugated geometry transforms a simple flat plate into a high-stiffness, low-weight structural element.
3Weight of moving object
If wing ribs are made lighter with composite materials, then flight characteristics are improved, but additional rib chords are needed increasing complexity
Solution Approach 1:
The corrugated web is designed to perform the load-distributing function traditionally performed by separate rib chords. The flutes of the corrugation act as natural load paths that transmit forces along the web, eliminating the need for additional internal reinforcement elements. This reduces the total number of components while maintaining structural performance.
Solution Approach 2:
The functions of the web and the rib chords are merged into a single integrated corrugated web structure. Instead of having a flat web plus separate chord members, the corrugated geometry combines the web's primary structural role with the chord's load-distribution role into one element, simplifying the overall rib construction.
Data Source
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AI summary
A wing includes an upper wing skin, a lower wing skin, and a wing rib positioned between the upper wing skin and the lower wing skin. The wing rib includes: a corrugated composite web comprising a wave pattern and a first fitting coupling said corrugated composite web with one of said upper wing skin and said lower wing skin.