Monolithic Blind Interface Joint for High-Aspect-Ratio Components
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Solution Overview
Problem
Joining aircraft components with high aspect ratios and differing materials poses challenges due to the need for mechanical strength and lightweight design, especially when attachment at inaccessible points is required.
Innovation Solution
A monolithic structure with Y-shaped spar fitting ends and a fitting element with blades that mate within the spars' channels, creating a bonded joint without mechanical fasteners, using composite or metallic materials and an adhesive agent for bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners (screws, bolts) are used to join components, then mechanical strength is improved, but weight increases and the solution becomes unsuitable for high aspect ratio components
Solution Approach 1:
The patent replaces mechanical fastening systems (screws, bolts, rivets) with a chemical bonding system using adhesives. The adhesive is applied to the interface between the spar fitting end and the component, creating a bond that joins the parts without mechanical fasteners. This substitution eliminates the weight penalty of metal fasteners while maintaining joint strength, and is particularly suitable for high aspect ratio components where drilling through the thin structure would be difficult or impossible.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical interlocking (fasteners) to chemical adhesion (adhesive bonding). This parameter change allows for a lighter weight solution while achieving sufficient mechanical strength. The adhesive creates a continuous bond across the joint interface, distributing loads differently than discrete mechanical fasteners, which enables weight reduction without sacrificing structural integrity.
2Strength
If mechanical fasteners are used to join components, then mechanical strength is improved, but the solution becomes inapplicable to inaccessible attachment points on high aspect ratio components
Solution Approach 1:
The patent replaces mechanical fastening systems with adhesive bonding, which eliminates the need for access to the other side of the component for fastener installation. The adhesive can be applied from one side only, making it ideal for high aspect ratio components where the back side is inaccessible. This substitution resolves the manufacturing difficulty while maintaining joint strength.
Solution Approach 2:
The adhesive acts as an intermediary substance that enables joining without requiring mechanical fasteners or access to both sides of the joint. It mediates the connection between the spar fitting end and the component, allowing bonds to form at inaccessible locations where traditional mechanical fastening would be impossible.
3Adaptability or versatility
If components of different materials (metallic and composite) are joined, then design flexibility is improved, but joining difficulty increases
Solution Approach 1:
The patent changes the joining mechanism from mechanical (fasteners requiring precise hole alignment and insertion) to chemical (adhesive bonding), which simplifies the joining process for dissimilar materials. The adhesive can accommodate slight misalignments and different material properties, reducing the complexity of joining metallic and composite components while maintaining design flexibility.
Solution Approach 2:
By replacing mechanical fastening with adhesive bonding, the patent eliminates the complexity associated with joining dissimilar materials through mechanical means. Adhesive bonding provides a more uniform stress distribution across the joint interface, avoiding stress concentrations that would occur with mechanical fasteners in composite materials, thereby simplifying the overall joining process.
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 solution provides a lightweight, strong, and durable component with internal blind joints, eliminating the need for external fasteners and ensuring mechanical integrity while maintaining cost-effectiveness.
Implementation Method 1
The one or more blades are bonded to the one or more spar fitting ends
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A component (20) is provided that includes a monolithic structure (24) and a fitting element (26). The monolithic structure (24) includes first and second outer panels (38), and spars (42) disposed between the first and second outer panels (38). The width (30) of the monolithic structure (24) extends between a fitting end (34) and a distal end (36). The spars (42) extend widthwise between the first and second outer panels (38). The spar fitting end (46) of each spar (42) has a Y-shaped configuration with first and second finger walls (48), and a channel (52) disposed there between. Both the first and second finger walls (48) have a divergent end (64A) and a distal end (36). The channel (52) has a closed end (68) and an open end (70) defined at the finger wall (48) distal ends (66A). The fitting element (26) has a body (80) with one or more blades (44) extending outwardly therefrom. Each blade (44) is received in and mates with a spar fitting end channel and is bonded to the spar fitting end.