Monolithic Composite Torsion Box for Aircraft Lifting Surfaces
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Solution Overview
Problem
The traditional manufacturing methods for aircraft torsion boxes using composite materials like CFRP are costly and complex due to the need for separate production and assembly of structural elements, leading to high weight and cost in aircraft lifting surfaces.
Innovation Solution
A method involving the use of laminated preforms configured to form parts of the main supporting structure, arranged in a curing assembly and subjected to an autoclave cycle for co-curing, allowing for a 'one-shot' manufacturing process that integrates leading and trailing edge ribs and aerodynamic profiles, reducing the number of components and fasteners.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate manufacture and assembly of structural elements is used, then manufacturing flexibility and ease of repair are maintained, but manufacturing cost and assembly complexity increase significantly
Solution Approach 1:
The patent merges multiple separate structural elements (skins, spars, ribs, stringers, leading edge, trailing edge) into a single integrated torsion box structure manufactured in one shot. This consolidation eliminates the need for separate manufacture and assembly of these elements, directly reducing manufacturing cost and assembly complexity while maintaining structural integrity through the integrated composite design.
2Strength
If multiple separate structural elements are assembled, then structural integrity can be maintained through proven assembly methods, but weight increases due to fasteners and joints
Solution Approach 1:
By consolidating all structural elements into a single monolithic torsion box, the invention eliminates the need for fasteners, joints, and connections between separate parts. This merging approach maintains structural integrity through the continuous composite material while removing the dead weight of assembly hardware, achieving both strength and weight reduction.
3Manufacturing precision
If traditional manufacturing processes are used for each element, then quality control and inspection are straightforward, but production time and cost increase
Solution Approach 1:
The invention incorporates all structural elements and their precise geometries into the single-shot manufacturing process from the beginning. The mold design includes integrated cavities for skins, spars, ribs, stringers, leading edge, and trailing edge, allowing all elements to be formed with precise dimensions and proper alignment in one curing cycle, eliminating subsequent assembly and inspection steps.
4Ease of manufacture
If separate manufacture of leading and trailing edges is performed, then ease of repair and replacement is maintained, but manufacturing cost and time increase
Solution Approach 1:
The leading edge and trailing edge are integrated into the single torsion box structure, eliminating separate manufacture and assembly. While this reduces manufacturing cost and complexity, the design incorporates features that allow for potential future repair or replacement of specific sections, balancing integration benefits with maintenance considerations.
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 approach results in weight and cost reductions by simplifying the manufacturing process and integrating structural elements, thereby enhancing efficiency and reducing the complexity of assembly.
Implementation Method 1
subjecting the curing assembly to an autoclave cycle to co-cure said laminated preforms
Data Source
AI summary
The invention provides an aircraft lifting surface with a monolithic main supporting structure (14) of a composite material comprising an upper skin (21) including at least a part of the upper aerodynamic profile of the leading edge (11) and/or of the trailing edge (15), a lower skin, a front spar (18), a rear spar (20), a plurality of leading edge ribs and/or a plurality of trailing edge ribs. This main supporting structure allows a weight and cost reduction of aircraft lifting surfaces. The invention also provides a manufacturing method of said monolithic main supporting structure (14).