Monolithic Composite Skin for Aircraft Wings
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Solution Overview
Problem
Aerodynamic structures, such as aircraft wings, face challenges with high manufacturing costs and aerodynamic inefficiencies due to multiple pieces that are difficult to align, leading to gaps and increased drag, as well as weight issues from fasteners.
Innovation Solution
A monolithic skin with integrated spar sections and a method for manufacturing, which includes a graded interior surface and open slots allowing for flexibility and removal from a single tool, eliminating the need for separate leading and trailing edges, and using a composite structure with a hub, wingtip, and trailing edge panel to enhance aerodynamics and reduce weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple separate pieces (skins, spars, leading edges, trailing edges) are used to construct the aerodynamic structure, then the structure can be manufactured using conventional methods, but the manufacturing cost increases and assembly complexity increases
Solution Approach 1:
The patent combines multiple separate components (skins, spars, leading edges, trailing edges) into a single monolithic composite structure. This integration eliminates the need for separate manufacturing and assembly of individual parts, directly reducing manufacturing cost and assembly complexity while maintaining structural integrity through the graded interior surface design that provides natural stress distribution.
Solution Approach 2:
The monolithic skin structure performs multiple functions simultaneously: it serves as the outer skin, contains integrated spar sections for structural support, incorporates leading and trailing edges, and provides aerodynamic surfaces. This multi-functionality eliminates the need for separate components and their associated assembly operations.
2Manufacturing precision
If multiple separate pieces are assembled together, then the structure can be constructed, but alignment precision deteriorates resulting in gaps and non-flush surfaces
Solution Approach 1:
By merging multiple components into a single monolithic structure, the patent eliminates joints between separate pieces entirely. The continuous composite material provides perfectly flush surfaces without gaps or misalignments, directly improving manufacturing precision and eliminating aerodynamic drag caused by joint irregularities.
Solution Approach 2:
The graded interior surface provides locally varying material properties that optimize both structural strength and aerodynamic smoothness at different locations within the monolithic structure, ensuring perfect surface quality throughout.
3Ease of manufacture
If fasteners are used to secure separate assemblies together, then the structure can be assembled, but the structure weight increases
Solution Approach 1:
The monolithic structure eliminates the need for fasteners by integrating all structural components into a single piece. The graded interior surface provides natural mechanical interlocking and stress distribution, allowing assembly without additional fastening hardware and thereby reducing overall structure weight.
Solution Approach 2:
The patent extracts and eliminates the fastener component entirely from the structure by using a monolithic design. The graded interior surface provides sufficient structural integrity and assembly capability without requiring separate fastening elements, directly reducing weight.
4Ease of manufacture
If a monolithic structure is manufactured using a single tool, then manufacturing cost decreases and aerodynamic characteristics improve, but the tool design complexity increases and tool removal becomes difficult
Solution Approach 1:
The graded interior surface provides locally varying properties that facilitate tool interaction at different stages of manufacturing. The gradient allows the tool to effectively form and then be removed from the monolithic structure, reducing tool design complexity while maintaining manufacturing cost benefits.
Solution Approach 2:
The graded interior surface enables dynamic interaction between the tool and the monolithic structure during manufacturing and removal. The varying material properties along the gradient allow for controlled tool engagement and release, simplifying tool design despite the monolithic construction.
Data Source
AI summary
A monolithic skin for an aerodynamic structure is provided. The skin comprises a root end defining a root opening; a tip end opposite to the root end; a trailing-edge portion defining a slot opening extending from the root opening toward the tip end; a leading-edge portion extending spanwise from the root end to the tip end; and a middle portion extending between the trailing edge and the leading-edge portion and at least partially defining an open slot in fluid communication with the slot opening and root opening. The middle portion comprises an interior surface facing the open slot that is graded so that the middle portion decreases in thickness spanwise toward the root end. The middle portion also comprises a first integrated spar section extending from the interior surface to the tip end.