Monolithic Aircraft Wing Spoiler Design for Moisture Resistance
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Solution Overview
Problem
Aircraft spoilers constructed with complex core-stiffened composite or metal bond assemblies face issues such as moisture ingress, thermal loading, mechanical distortion, and high manufacturing costs due to the use of multiple materials and metallic attachment lugs, which increase maintenance and production expenses.
Innovation Solution
The development of a monolithic structural body for spoilers made from materials like aluminum, titanium, or steel, constructed using techniques like machining or additive manufacturing, eliminating honeycomb core structures and sandwich panels, and featuring integral lugs and flexible trailing edges for robustness and reduced moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If complex core-stiffened composite or metal bond assemblies with metallic attachment lugs are used, then structural strength and aerodynamic performance are improved, but moisture ingress, thermal loading, and manufacturing costs increase
Solution Approach 1:
The patent merges multiple separate components (core structure, stiffening elements, and attachment lugs) into a single monolithic spoiler body. This integration eliminates the interfaces between components where moisture could ingress, while maintaining structural strength through the unified geometry and material composition of the monolithic structure.
Solution Approach 2:
The patent employs composite materials in the monolithic spoiler body, combining different materials with complementary properties to achieve both structural strength and resistance to moisture ingress. The composite material formulation allows the single-piece structure to simultaneously provide mechanical strength and environmental protection without requiring separate protective components.
2Strength
If multiple materials and metallic attachment lugs are assembled, then aerodynamic performance and structural integrity are improved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent combines multiple separately manufactured components into a single monolithic spoiler body that can be produced as one integrated piece. This merging approach eliminates the need for complex assembly operations involving multiple materials and metallic attachment lugs, significantly reducing manufacturing complexity while preserving structural integrity through the unified design.
Solution Approach 2:
The patent changes the manufacturing parameters from traditional multi-step assembly processes to advanced monolithic fabrication techniques such as additive manufacturing or single-piece machining. This parameter change enables the production of complex geometries with integrated stiffening elements and attachment features in a single manufacturing operation, reducing both complexity and cost.
3Strength
If metallic attachment lugs are mechanically fastened and sealed, then connection strength is improved, but thermal loading and maintenance costs increase
Solution Approach 1:
The patent merges the attachment lugs into the monolithic spoiler body, eliminating separate metallic attachment components. This integration removes the thermal interfaces and potential distortion points associated with mechanically fastened lugs, while connection strength is maintained through the continuous material structure and optimized geometry of the integrated design.
Solution Approach 2:
The patent uses composite materials in the monolithic structure that exhibit superior thermal stability compared to traditional metallic attachment lugs. The composite material formulation provides resistance to thermal loading and prevents the thermal expansion mismatches and distortion issues that arise with metallic components subjected to temperature variations.
Data Source
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AI summary
The disclosure relates to aircraft wings, aircraft, and related methods. Aircraft wings include a spoiler constructed substantially of a monolithic structural body with an upper side that defines a portion of an airfoil surface of an aircraft wing. The monolithic structural body further includes a lower side, opposite the upper side, that includes a plurality of stiffening ribs that define a plurality of open voids. Methods of constructing a spoiler for an aircraft wing include forming a monolithic structural body of the spoiler.