Fiber-Composite Torsion Box Integration for Aircraft Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing of torsion boxes for aircraft structures with complex stiffening components is labor-intensive and requires substantial effort due to the need for separate production and riveted connections, which can affect weight and design.
Innovation Solution
A method involving the superimposition of two fiber composite components, each with their own stiffening elements, allowing for cohesive production without additional weight or design changes, using vacuum infusion or resin transfer molding to integrate stiffening elements with the base, reducing the need for riveted connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate flat shells are produced and stiffening components are riveted to them, then complex stiffening components can be provided, but the manufacturing effort required is substantial and additional weight is introduced
Solution Approach 1:
The patent combines the flat shell and stiffening components into a single integrated fiber composite component. The stiffening elements are arranged on the inner side of the flat shell during manufacturing, and both are impregnated with resin simultaneously through vacuum infusion or resin transfer molding. This merging eliminates the need for separate production and riveted connections, thereby reducing manufacturing effort while maintaining the complexity of stiffening components.
2Adaptability or versatility
If separate flat shells are produced and stiffening components are riveted to them, then complex stiffening components can be provided, but the weight increases due to riveted connections
Solution Approach 1:
The flat shell and stiffening components are merged into a single integrated fiber composite component manufactured using vacuum infusion or resin transfer molding. This eliminates riveted connections and the associated weight, while preserving the complex stiffening geometry through integrated design.
3Ease of manufacture
If a vacuum film is used to impregnate the semi-finished fiber product, then the impregnation process is simplified, but the vacuum film must be flush with stiffening components and gaps, requiring prevention of wrinkling
Solution Approach 1:
The patent segments the fiber reinforcement into a base fabric and separate stiffening element fabrics. The stiffening element fabrics are arranged on the inner side of the base fabric in the desired final positions before impregnation. This segmentation allows the vacuum film to conform to the overall outer shape without needing to navigate complex gaps and protrusions, simplifying the vacuum film arrangement while maintaining ease of impregnation.
4Reliability
If riveted connections are made to connect separate components, then structural integrity can be achieved, but the fiber course has to be adapted or dimensioned accordingly
Solution Approach 1:
The patent merges the flat shell and stiffening components into a single integrated fiber composite component manufactured using vacuum infusion or resin transfer molding. This eliminates riveted connections and the associated need for fiber course adaptation, while preserving structural integrity through continuous fiber reinforcement throughout the integrated structure.
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 method significantly reduces manufacturing effort by half while maintaining mechanical integrity and force flow, achieving a robust and lightweight torsion box with reduced riveted connections.
Implementation Method 1
the vacuum film can easily follow the flat extent of the component concerned
Implementation Method 2
In order to impregnate the semi-finished fiber product with resin, the scrim that has been produced is frequently covered with a vacuum film
Data Source
AI summary
A method for producing a torsion box for a structure of an airplane. The method includes providing a first component made of a fiber composite material, the first component has a first planar base having a first inner side and a first outer side, first stiffening elements on the first inner side forming a composite with the first base. A second component is provided of a fiber composite material and has a second planar base having a second inner side and a second outer side. Second stiffening elements are on the second inner side and form a composite with the second base. The method includes superimposing the first component and the second component such that the first stiffening elements lie, at least in some areas, on the second inner side and the second stiffening elements lie, at least in some areas, on the first inner side. The methods includes connecting the first stiffening elements to the second base and connecting the second stiffening elements to the first base.