Monolithic Aircraft Control Surface Fabrication via Resin Injection
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Solution Overview
Problem
Existing methods for fabricating aircraft control surfaces often struggle to achieve a balance between weight reduction and maintaining structural integrity, particularly in withstanding aerodynamic forces over the operational life of the aircraft.
Innovation Solution
A tool and method for fabricating control surfaces that involve positioning a shell about a tool defining an internal channel and a hollow trailing edge region, injecting resin into these areas, and cooling it to form stringers and a solid trailing edge region, thereby creating a monolithic control surface with enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If hollow airfoil-like bodies with stringers and solid material sections are used, then weight is reduced and strength is improved, but manufacturing complexity increases
Solution Approach 1:
The patent uses a pre-configured tool with defined internal channels and hollow trailing edge regions that guides the resin injection process. The tool is positioned about the mold cavity before resin injection, establishing predetermined flow paths and solidification regions in advance, which simplifies the manufacturing process while achieving the desired complex internal structure
Solution Approach 2:
The patent controls the phase transition of resin from liquid to solid through temperature changes. By injecting resin in liquid form and then cooling it within the defined channels and regions, the process achieves complex structural formation through parameter change rather than complex mechanical assembly
2Strength
If resin is injected into internal channels and hollow trailing edge regions, then structural integrity is enhanced, but manufacturing time increases
Solution Approach 1:
The patent employs continuous resin injection into the internal channels and hollow trailing edge regions without interruption. The resin flows continuously through the defined paths and solidifies in place, eliminating the need for multiple separate operations and reducing overall manufacturing time while ensuring complete structural integrity
Solution Approach 2:
The patent rapidly fills the internal channels and hollow trailing edge regions with resin in a single injection cycle rather than using incremental filling. This rushing through the process minimizes the time the resin remains in a vulnerable liquid state and accelerates production while maintaining structural 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 approach results in control surfaces that are lightweight yet possess high strength and structural integrity, effectively withstanding aerodynamic forces and ensuring the safety and performance of aircraft during flight.
Implementation Method 1
cooling it to form stringers and a solid trailing edge region
Data Source
AI summary
A monolithic control surface includes an upper shell portion, a lower shell portion, a stringer connected to the upper shell portion and the lower shell portion, a trailing edge end, and a solid trailing edge region connected to the upper shell portion, the lower shell portion and the stringer.