Flat Composite Panel With Integrated Tear Straps
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Solution Overview
Problem
Flat composite panels used in aircraft pressure decks face challenges in impact damage resistance and repair due to their thinness and requirement for external stiffeners, which complicate both the manufacturing and repair processes.
Innovation Solution
A flat composite panel with integrated tear arrestment features, comprising a base panel made of fiber-reinforced polymer with interspersed first and second tear straps oriented in orthogonal directions, which enhances the panel's stiffness and resistance to impact damage without the need for external stiffeners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If external stiffeners are added to increase panel stiffness, then the panel stiffness is improved, but the device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the stiffener function directly into the panel structure by integrating longitudinal and transverse tear straps within the laminate layers. This eliminates the need for separate external stiffeners while maintaining the required stiffness through the integrated tear arrestment features that prevent damage propagation.
Solution Approach 2:
The patent uses composite materials by combining fiber-reinforced polymer plies with tear straps in a multi-layer laminate structure. The composite construction integrates the stiffening function throughout the panel thickness, achieving enhanced stiffness without additional external components.
2Manufacturing precision
If specialized tooling is used for co-curing stiffeners with panel, then the manufacturing precision is improved, but the manufacturing cost and complexity increase
Solution Approach 1:
The patent extracts the stiffener function from separate components and integrates it directly into the panel laminate structure. This eliminates the need for specialized co-curing tooling while maintaining manufacturing precision through the integrated tear strap design that is formed as part of the panel itself.
3Reliability
If impact damage occurs to the panel, then the structural integrity is compromised, but the repair process becomes time-consuming and complex
Solution Approach 1:
The patent applies preliminary anti-action by incorporating tear straps that prevent damage propagation before full structural failure occurs. The integrated tear arrestment features stop crack propagation paths, maintaining structural integrity and simplifying repair by limiting the extent of damage that needs to be addressed.
4Weight of moving object
If the panel is made thinner to reduce weight, then the weight is reduced, but the impact damage resistance decreases
Solution Approach 1:
The patent uses composite materials with fiber-reinforced polymer plies and integrated tear straps to achieve high impact resistance in thin-panel configurations. The multi-layer composite structure provides damage tolerance without requiring increased thickness, maintaining weight efficiency while improving impact resistance.
Data Source
AI summary
A pressure deck for an aircraft comprises a flat composite laminate base panel having integrated tear straps to enhance damage arrestment. The tear straps include a plurality of multi-ply, spaced apart longitudinal and lateral tear straps interspersed with the plies of the base panel.