Integrally Curved Composite Aircraft Panel Channel
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Solution Overview
Problem
Existing aircraft panels with discrete channels for receiving hinge members are prone to stress concentrations at connecting points, such as welds or bolts, which can compromise the panel's resilience and structural integrity.
Innovation Solution
An aircraft panel comprising a ply of composite material curved around an axis such that the free end extends more than 180 degrees, forming an integrally curved channel that reduces stress concentrations and provides improved structural resilience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If discrete channels are connected to the aircraft panel using connecting parts (welds or bolts), then the channel can be separately manufactured and installed, but stress concentrations occur at the connecting points which compromises panel resilience and structural integrity
Solution Approach 1:
The channel is integrated directly into the aircraft panel structure, eliminating the need for separate connecting parts. The channel forms as an integral part of the panel during manufacturing, which removes stress concentration points while maintaining ease of manufacture through streamlined production processes.
Solution Approach 2:
The channel is designed as a segmented structure with multiple walls formed by curving the ply of composite material around an axis. This segmentation allows the channel to distribute stresses across multiple structural elements rather than concentrating them at single connection points, thereby improving overall strength.
2Ease of manufacture
If discrete channels are used with connecting parts, then manufacturing flexibility is improved, but the panel weight increases due to additional connecting components
Solution Approach 1:
The channel and aircraft panel are merged into a single integrated structure, eliminating the weight of separate connecting parts such as welds, bolts, and associated hardware. This integration maintains manufacturing flexibility while significantly reducing overall panel weight.
3Ease of manufacture
If the free end of the ply extends less than 180 degrees around the axis, then the manufacturing process is simpler, but the channel is less effective at restricting radial movement of the hinge member
Solution Approach 1:
The free end of the ply is curved around the axis to extend more than 180 degrees, creating a channel with enhanced circumferential coverage. This curvature configuration provides superior restriction of radial movement of the hinge member while remaining compatible with standard composite material forming processes.
4Ease of manufacture
If the transition region contains inflection points in the curve, then the manufacturing process is simpler, but the tensile load distribution through the fibre becomes non-uniform reducing panel strength
Solution Approach 1:
The transition region is designed with specific local quality characteristics - the curve is configured to be free of inflection points, creating a monotonic transition that ensures uniform tensile load distribution through the fibre. This localized design feature maintains manufacturing simplicity while significantly improving structural strength.
Data Source
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AI summary
Disclosed is an aircraft panel comprising a ply of composite material, the ply of composite material curved around an axis such that a free end of the ply extends more than 180 degrees around the axis and defines a wall of a channel for receiving a hinge member of an aircraft component.