Monolithic Composite Under-Wing Pylon Design
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Solution Overview
Problem
Existing under-wing pylons made of both metal and composite materials face implementation challenges due to structural complexity and the need for substantial load transport within aerodynamic and dimensional constraints.
Innovation Solution
A monolithic under-wing pylon made from a stratified framework of carbon fibers, either unidirectional or woven, impregnated with epoxy resin, providing increased rigidity and reduced weight through a single, integrated composite structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If under-wing pylons are made of assembled metal and composite material parts, then structural capacity to transport substantial loads can be achieved, but the device complexity increases and manufacturing becomes more difficult
Solution Approach 1:
The patent merges multiple separate parts (metal elements and composite material elements) into a single monolithic structure made entirely of composite material. This integration eliminates the need for assembly between different material types, reducing device complexity while maintaining the structural capacity to transport substantial loads through the unified composite framework.
Solution Approach 2:
The patent employs composite materials (specifically fibreglass or similar composite materials) to replace the previous combination of metal and composite parts. This allows the creation of a monolithic structure that achieves the required structural capacity while simplifying manufacturing, as the entire pylon can be formed through composite layup and curing processes rather than assembling multiple parts.
2Strength
If under-wing pylons use assembled metal and composite material parts, then structural capacity for substantial loads can be achieved, but manufacturing precision and implementation reliability decrease
Solution Approach 1:
By combining all structural elements into a single monolithic composite structure, the patent eliminates the need for precise assembly operations between metal and composite parts. The manufacturing precision requirement shifts to the composite layup and curing process, which can achieve high precision through controlled manufacturing methods, thereby improving overall implementation reliability.
3Strength
If under-wing pylons are made of assembled metal and composite material parts, then structural capacity to transport substantial loads can be achieved, but the weight increases
Solution Approach 1:
The patent uses composite materials (fibreglass or similar composites) to replace metal elements in the pylon structure. Composite materials typically have higher strength-to-weight ratios compared to metals, allowing the monolithic structure to achieve the required structural capacity for transporting substantial loads while significantly reducing the overall weight of the pylon.
4Strength
If under-wing pylons use assembled metal and composite material parts, then structural capacity can be achieved, but the ease of manufacture decreases
Solution Approach 1:
By merging all parts into a single monolithic composite structure, the patent simplifies the manufacturing process. Instead of manufacturing separate metal and composite parts and then assembling them with precise alignment and fastening operations, the entire pylon can be manufactured in one continuous composite layup and curing process, significantly improving ease of manufacture.
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
The solution enhances structural rigidity while reducing weight, facilitating the transport of substantial loads while adhering to aerodynamic and dimensional requirements.
Implementation Method 1
a monolithic framework made through a stratification of carbon fibres, unidirectional and/or woven, impregnated with epoxy resin
Data Source
AI summary
Under-wing pylon for an aircraft which has on the upper side a pin (2) for attaching to the fuselage or to the wings of the aircraft itself, and a connector (3) for connecting the pylon to the aircraft. The pylon has a monolithic framework made with stratified unidirectional and/or woven carbon fibres, impregnated with epoxy resin.