Interlaced Nonlinear Panel Edges for Weight Reduction
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Solution Overview
Problem
Existing panel assemblies for aircraft and other structures require multiple rows of fasteners, increasing weight and manufacturing costs due to the use of heavier materials in edgebands, which also results in a larger edgeband width and increased fastener count.
Innovation Solution
The implementation of panel assemblies with nonlinear edges that interlace to form a reduced-width edgeband, allowing for a lighter weight structure by using thinner edgebands and reducing the number of fasteners needed for assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple rows of fasteners are used to join panel assemblies, then the structural strength and reliability are improved, but the weight of the assembly increases due to heavier edgebands and more fasteners
Solution Approach 1:
The patent applies curved or scalloped edge profiles instead of straight edges, creating interdigitated patterns that mechanically interlock panels. This curved geometry provides structural strength through the interlocking mechanism while reducing the need for multiple fastener rows, thereby reducing overall assembly weight.
Solution Approach 2:
The edgebands are designed with interdigitated patterns where protrusions and recessions nest together to form an interlocked structure. This nesting mechanism creates a mechanically strong joint that reduces dependency on numerous fasteners, thus improving strength-to-weight ratio.
2Reliability
If heavier materials are used in edgebands to provide structural strength, then the reliability of the panel assembly is improved, but the overall weight of the structure increases
Solution Approach 1:
The curved or scalloped edge profiles create mechanical interlocking through geometry rather than relying solely on material weight. This allows the use of lighter materials while maintaining structural reliability through the interdigitated mechanical connection.
Solution Approach 2:
The patent employs composite material construction in the edgebands, combining materials with different properties to achieve high strength-to-weight ratio. This allows the edgebands to provide necessary structural strength without excessive weight.
3Reliability
If a larger edgeband width is used to accommodate multiple rows of fasteners, then the structural reliability is improved, but the manufacturing cost increases due to more materials and fasteners
Solution Approach 1:
The curved edge profiles create mechanical interlocking that provides structural reliability without requiring wide edgebands to accommodate multiple fastener rows. This reduces material consumption and manufacturing cost while maintaining reliability.
Solution Approach 2:
The invention extracts the fastening function from the edgeband width dimension by creating self-interlocking curved profiles. This eliminates the need for wide edgebands with multiple fastener rows, reducing material usage and manufacturing complexity.
4Strength
If multiple rows of fasteners are used to join panels, then the structural strength is improved, but the number of fasteners and assembly complexity increases
Solution Approach 1:
The curved or scalloped edge profiles create mechanical interlocking that provides joint strength through geometry rather than through multiple fasteners. This reduces assembly complexity and fastener count while maintaining joint strength.
Solution Approach 2:
The interdigitated patterns with protrusions and recessions nest together to form a mechanically strong joint. This nesting mechanism eliminates the need for multiple fastener rows, reducing both fastener count and assembly complexity while maintaining joint strength.
Data Source
AI summary
In an embodiment of the disclosure, there is provided a panel assembly for joining to a structure and method of making the same. The assembly has a first panel element having at least one first panel nonlinear edge, and has a second panel element having at least one second panel nonlinear edge, wherein the second panel nonlinear edge is designed to interlace with the first panel nonlinear edge to form a panel assembly with interlaced panel edgebands for joining to a structure. A width of the interlaced panel edgebands is reduced as compared to a width of adjacent panel edgebands formed by adjacent panel elements having linear edges, and the reduced width results in an overall reduced weight of the panel assembly and the structure to which the panel assembly is joined.