Dual-Resin Textile Composite for Flexible Aircraft Gap Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite materials used in aircraft structures are too rigid and brittle to effectively cover or seal gaps between fixed and moving surfaces, lacking the necessary flexibility and shear strength to withstand aerodynamic forces while minimizing drag and acoustic signatures.
Innovation Solution
A composite structure featuring a textile arrangement with a distribution of pores filled by two resins of different elastic moduli, where a rigid first resin fills smaller pores and a flexible second resin fills larger pores, creating a non-porous, selectively deformable material with enhanced shear strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite materials are used to provide mechanical strength and shear strength, then strength is improved, but flexibility deteriorates
Solution Approach 1:
The patent applies local quality by using two different resins with different elastic moduli in different regions of the composite material. The first resin (higher elastic modulus) is placed in fiber-rich regions where high strength is needed, while the second resin (lower elastic modulus) is placed in fiber-poor regions where flexibility is needed. This spatial differentiation of material properties resolves the contradiction between strength and flexibility.
Solution Approach 2:
The patent uses composite materials by combining textile fibers with two different resins to create a multi-phase composite structure. The textile fibers provide the reinforcing skeleton, while the two resins with different mechanical properties (different elastic moduli) are distributed throughout the structure to simultaneously provide both strength and flexibility.
2Adaptability or versatility
If flexible materials are used to cover aircraft skin, then flexibility is improved, but shear strength deteriorates
Solution Approach 1:
The patent applies local quality by strategically placing the first resin (higher elastic modulus) in fiber-rich regions where high shear strength is required to withstand aerodynamic forces, while the second resin (lower elastic modulus) is placed in fiber-poor regions where flexibility is prioritized for conforming to aircraft surfaces.
Solution Approach 2:
The patent uses composite materials by combining textile fibers with two different resins to create a multi-phase composite structure. The textile fibers provide the reinforcing skeleton, while the two resins with different mechanical properties (different elastic moduli) are distributed throughout the structure to simultaneously provide both strength and flexibility.
3Strength
If rigid composite materials are used to withstand aerodynamic forces, then shear strength is improved, but ability to seal gaps between moving surfaces deteriorates
Solution Approach 1:
The patent applies local quality by using the second resin (lower elastic modulus) in fiber-poor regions and at interfaces where gap sealing is critical, allowing these regions to deform and conform to moving surfaces while the first resin (higher elastic modulus) in fiber-rich regions provides the necessary shear strength.
4Adaptability or versatility
If flexible materials are used to close gaps between control surfaces, then gap sealing is improved, but mechanical stability deteriorates
Solution Approach 1:
The patent applies local quality by strategically placing the first resin (higher elastic modulus) in fiber-rich regions where mechanical stability is critical for maintaining structural integrity, while the second resin (lower elastic modulus) is placed in fiber-poor regions where flexibility for gap sealing is prioritized.
Solution Approach 2:
The patent uses composite materials by combining textile fibers with two different resins to create a multi-phase composite structure. The textile fibers provide the reinforcing skeleton, while the two resins with different mechanical properties (different elastic moduli) are distributed throughout the structure to simultaneously provide both strength and flexibility.
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
The composite structure achieves a balance of mechanical strength and flexibility, reducing drag and acoustic signatures by filling gaps between aircraft surfaces while maintaining structural integrity under aerodynamic forces.
Implementation Method 1
a first resin fills the intra-fiber pores and also those inter-fiber pores having a pore diameter equal to or less than a pore diameter threshold
Implementation Method 2
a second resin bonds to the first resin and substantially fills those inter-fiber pores having a pore diameter greater than the pore diameter threshold
Data Source
Figure 1~3
Figure 4~5
Figure 6
AI summary
Solid, flexible composite structures (10) including a textile arrangement (12) of at least one textile layer (22) constructed of textile fibers (20) and having a distribution of pores (30) formed therein, with a first resin (14) filling pores having a pore diameter equal to or less than a pore diameter threshold, and a second resin (16) bonded to the first resin and substantially filling pores having a pore diameter greater than the pore diameter threshold. Some embodiments include a rigid first resin such as an epoxy, and a flexible second resin such as a silicone.