Monolithic Composite Trailing Edge Panel with Integrated Stiffeners

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Solution Overview

Problem

Composite sandwich panels with honeycomb or foam cores are not suitable for trailing edges due to difficulty in achieving a small radius of curvature and maintaining aerodynamic continuity, which affects aircraft performance, and require complex assembly processes.

Innovation Solution

A single-piece composite structural panel with integrated transverse stiffeners and longitudinal spars, manufactured using a process involving core deposition, draping, folding, and polymerization to form a monolithic skin, which simplifies production and enhances structural strength and aerodynamic continuity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If composite sandwich panels with honeycomb or foam cores are used, then mass reduction is achieved, but the ability to achieve small radius of curvature and maintain aerodynamic continuity deteriorates

Engineering Contradiction:

ImprovemassVSAvoidradius of curvature

Core Design Contradiction:

Weight of moving objectVSShape

Solution Approach 1:

The panel is divided into a skin layer and integrated stiffener elements that form during the molding process. The stiffeners are created by folding the skin over cores, creating a segmented structural system that maintains flexibility for curvature while providing structural strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the structural parameters by using a monolithic skin construction without traditional honeycomb or foam cores, allowing the panel to achieve small radius of curvature while maintaining aerodynamic continuity through integrated stiffeners rather than bulky core structures.

Inventive Principle:

Principle #35Parameter changes

2Weight of moving object

If composite sandwich panels with honeycomb or foam cores are used, then mass reduction is achieved, but aerodynamic continuity deteriorates

Engineering Contradiction:

ImprovemassVSAvoidaerodynamic continuity

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The skin and stiffeners are merged into a single monolithic structure formed by folding the skin over cores during molding. This eliminates joints and interfaces that would disrupt aerodynamic flow, while the integrated design maintains mass efficiency compared to traditional sandwich panels.

Inventive Principle:

Principle #5Merging (Combining)

3Weight of moving object

If traditional composite sandwich panels are used, then mass reduction is achieved, but manufacturing complexity increases

Engineering Contradiction:

ImprovemassVSAvoidassembly process

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

Multiple components (skin, stiffeners, and structural elements) are merged into a single monolithic piece formed during one molding cycle. The skin is folded over cores to create stiffeners that are permanently integrated, eliminating the need for separate assembly steps and reducing manufacturing complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The stiffeners are formed in advance during the molding process by folding the skin over cores before final curing. This preliminary formation of structural elements eliminates the need for post-molding assembly operations, simplifying the overall manufacturing process while maintaining mass efficiency.

Inventive Principle:

Principle #10Preliminary action

4Shape

If small radius of curvature is achieved at the trailing edge, then aerodynamic continuity is improved, but structural strength deteriorates

Engineering Contradiction:

Improveaerodynamic continuityVSAvoidstructural strength

Core Design Contradiction:

ShapeVSStrength

Solution Approach 1:

The panel has different structural properties at different locations: the skin is thin and flexible at the trailing edge to achieve small radius of curvature and aerodynamic continuity, while integrated stiffeners are formed at strategic locations to provide local structural strength where needed without compromising the curved shape.

Inventive Principle:

Principle #3Local quality

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 provides excellent aerodynamic continuity, improved structural mechanical resistance, and simplified manufacturing by eliminating the need for assembly, while effectively managing buckling and optimizing mass distribution for trailing edge applications.

Implementation Method 1

a third step (C) in which the panel thus obtained is polymerized so as to integrate the folds of the layup in the base skin to form the transverse stiffeners

Methodology Applied

Scientific EffectPolymerization: Photopolymerisation

Data Source

PatentEP2435301B1Method for manufacturing a composite structuring panel for the trailing edge of an aircraft element

Publication Date: 2019.05.01 SOC LORRAINE DE CONSTR AERONAUTIQUE SLCA

Figure 1~5
Figure 6~7

AI summary

The invention relates to a composite structuring panel (1) for the trailing edge of an aircraft element, having: an upper surface (3); a lower surface (5); an edge (7) connecting said upper (3) and lower (5) surfaces; the upper surface (3) and the lower surface (5) being connected by transverse stiffeners (9) and the structuring panel being made of a unitary part forming the upper surface (3), the lower surface (5), the edge (7), and the transverse stiffeners (9). The invention also relates to a method for manufacturing such a panel (1), and to an aircraft element comprising such a panel (1).