Load Introduction Structure for Composite Skin Attachment

Solution Overview

Problem

The design of fiber-reinforced aerodynamic structures faces challenges in load transmission, particularly the 'unfolding' of layers, while requiring low manufacturing/assembly costs and stable processes.

Innovation Solution

A load introduction system with a longitudinal connection element that anchors to the upper and lower skin sections of an aerodynamic structure, pulling the attachment unit against the lower skin, thereby transferring loads while avoiding material unfolding and simplifying assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If fiber reinforced materials are used to reduce the number of parts, then manufacturing cost is reduced, but the design process becomes more challenging due to material behavior issues like layer unfolding

Engineering Contradiction:

Improvemanufacturing costVSAvoiddesign process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The attachment unit is divided into distinct functional components: a base section for mounting to the aerodynamic structure, an attachment section for connecting to the drive system, and a reinforcement element. This segmentation allows each component to be optimized for its specific function while maintaining overall simplicity in the fiber reinforced material design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reinforcement element is pre-configured with a specific geometry and material composition that prevents layer unfolding during the attachment process. By designing the reinforcement element to inherently resist deformation, the patent eliminates the need for complex real-time monitoring and adjustment mechanisms during assembly

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If traditional attachment methods are used for aerodynamic structures, then assembly is simple, but load transmission causes layer unfolding in fiber reinforced materials reducing structural stability

Engineering Contradiction:

Improveassembly simplicityVSAvoidstructural stability

Core Design Contradiction:

Ease of operationVSStability of the object's composition

Solution Approach 1:

The reinforcement element is pre-configured with a specific geometry and material composition that prevents layer unfolding during the attachment process. By designing the reinforcement element to inherently resist deformation, the patent eliminates the need for complex real-time monitoring and adjustment mechanisms during assembly

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The attachment unit utilizes fiber reinforced materials with specific fiber orientations and stacking sequences that provide both ease of assembly and structural stability. The reinforcement element incorporates multiple layers of fiber reinforced material with alternating fiber directions to resist loads from different directions while maintaining a closed-box structure

Inventive Principle:

Principle #40Composite materials

3Weight of moving object

If fiber reinforced aerodynamic structures are used, then weight is reduced, but load transmission becomes more difficult due to material behavior

Engineering Contradiction:

Improveaerodynamic structure weightVSAvoidload transmission capability

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The attachment unit utilizes fiber reinforced materials with specific fiber orientations and stacking sequences that provide both ease of assembly and structural stability. The reinforcement element incorporates multiple layers of fiber reinforced material with alternating fiber directions to resist loads from different directions while maintaining a closed-box structure

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The reinforcement element is designed with varying fiber orientations and material properties at different locations to optimize load transmission. The local fiber arrangement is tailored to match the stress distribution patterns expected during operation, providing enhanced strength where needed while maintaining overall weight efficiency

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS12441457B2Load introduction system and a method for manufacturing a load introduction system

Publication Date: 2025.10.14 AIRBUS OPERATIONS GMBH

AI summary

A load introduction system is disclosed including an aerodynamic structure component having an upper skin section and a lower skin section, an attachment unit and a load introduction unit configured to couple the attachment unit to the aerodynamic structure component. The load introduction unit includes a longitudinal connection element with its first end positioned at the upper skin section. The longitudinal connection element extends through the lower skin section such that its second end is positioned outside of the aerodynamic structure component. The first end is anchored to the upper skin section and the second end is anchored to the attachment unit such that the longitudinal connection element forces the attachment unit against the lower skin section.