Monolithic Composite Wing Structure Manufacturing
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Solution Overview
Problem
Current methods for manufacturing wing structures using composite materials require multiple mechanical assembly operations, leading to increased production costs and weight, as well as potential aerodynamic and radar signature issues due to metallic parts.
Innovation Solution
A method to create a monolithic wing structure by polymerizing composite material panels, spars, leading edges, and trailing edges in a closed mould, forming an integral profile with minimized mechanical assembly, reducing drag and radar signature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mechanical assembly operations are used to attach leading edge and trailing edge to wing structure, then structural integrity is maintained, but production cost and weight increase
Solution Approach 1:
The patent merges the leading edge, trailing edge, and wing box structure into a single monolithic composite component manufactured through one continuous process. This eliminates separate mechanical assembly operations, reducing production cost and weight while maintaining structural integrity through integrated load paths.
Solution Approach 2:
The leading edge and trailing edge are pre-formed as integral extensions of the wing box structure during the initial manufacturing process. This preliminary action eliminates the need for subsequent mechanical attachment operations, reducing both cost and weight while preserving structural strength.
2Ease of manufacture
If mechanical connecting members are used to assemble wing structure components, then structural strength is maintained, but weight and production cost increase
Solution Approach 1:
The patent combines multiple wing structure components into a single monolithic composite part, eliminating the need for mechanical connecting members. This integration removes the weight of fasteners, joints, and assembly hardware while simplifying manufacturing and reducing production costs.
Solution Approach 2:
The patent extracts and eliminates mechanical connecting members from the wing structure assembly. By designing the leading edge and trailing edge as integral composite extensions, the solution removes unnecessary weight while maintaining structural strength through the composite material itself.
3Strength
If metallic parts are present in wing structure, then structural strength is provided, but aerodynamic quality and radar signature are degraded
Solution Approach 1:
The patent uses composite materials throughout the entire wing structure, including the leading edge and trailing edge. This eliminates metallic parts that would degrade aerodynamic quality and increase radar signature, while the composite material itself provides the necessary structural strength through its high strength-to-weight ratio and tailored fiber orientations.
4Productivity
If multiple assembly operations are performed, then structural components can be manufactured separately, but manufacturing complexity and time increase
Solution Approach 1:
The patent merges the manufacturing of the wing box structure, leading edge, and trailing edge into a single continuous process. This eliminates multiple assembly operations, reducing manufacturing time and complexity while producing a monolithic structure with integrated load paths and superior aerodynamic 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
This approach significantly reduces mechanical assembly operations, production costs, weight, drag, and radar signature, while enhancing structural integrity and reducing fatigue and corrosion risks.
Implementation Method 1
polymerizing the entire structure in a closed mould
Data Source
AI summary
A method of manufacturing a wing structure includes laying a plurality of layers of preimpregnated material on a first mould half and on a second mold half so as to form a first fresh skin and a second fresh skin of the wing structure. A plurality of layers of preimpregnated material are laid in succession on a shaped apparatus to form a fresh leading edge skin of the wing structure. Fresh spars of preimpregnated material are formed. A wedgelike body of expanded plastics material is formed, this body being designed to be interposed between the first and second skins at the trailing edge of the wing structure. The fresh spars are positioned in a coordinated way on the first fresh skin, removable support members also positioned next to the spars. The second mold half is turned over on to the first mold half so as to position the second fresh skin on the spars and the supports, to produce a fresh wing structure. The fresh wing structure is subjected to a polymerization cycle, using a vacuum bag.