Monolithic Wing Fuselage Joint Assembly

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Solution Overview

Problem

Current aircraft fuselage-to-wing joint assembly methods are complex, heavy, and costly due to the use of numerous fasteners and segmented metal parts, which increase weight and assembly time, and fail to effectively contain damage propagation in composite aircraft structures.

Innovation Solution

A monolithic joint system comprising a first vertical flange, a base plate, and a second vertical flange formed from a continuous piece of material, with integrated damage containment features that slow crack propagation, eliminating the need for fasteners and allowing for a single-piece assembly of the upper chord assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If traditional fuselage-to-wing joint assembly methods are used with numerous fasteners and segmented metal parts, then structural connection is achieved, but weight increases and assembly time increases

Engineering Contradiction:

Improveaircraft weightVSAvoidjoint assembly complexity

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The patent merges multiple separate components (vertical flanges, base plate, splicing members) into a single monolithic upper chord assembly formed from one piece of material. This eliminates the need for numerous fasteners and reduces assembly complexity while maintaining structural connection functionality between the fuselage and wing.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The monolithic upper chord assembly performs multiple functions simultaneously: it connects the fuselage to the wing, provides structural support, and incorporates damage containment features all within a single component. This multi-functionality reduces the overall number of parts needed in the joint assembly.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If traditional fuselage-to-wing joint assembly methods are used with numerous fasteners and segmented metal parts, then structural connection is achieved, but assembly time increases

Engineering Contradiction:

Improveassembly speedVSAvoidassembly time

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

By combining multiple components into a single monolithic upper chord assembly, the number of assembly steps is dramatically reduced. The single-piece construction eliminates the time required to assemble multiple separate parts and fasteners, thereby increasing assembly productivity.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If traditional joint assembly methods are used, then structural connection is achieved, but damage containment is insufficient in composite aircraft

Engineering Contradiction:

Improvedamage containment capabilityVSAvoidjoint structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The monolithic construction integrates damage containment features directly into the upper chord assembly itself, rather than requiring separate damage containment components. This merging of functions maintains reliable damage containment while reducing overall structural complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent specifies that the monolithic upper chord assembly may be formed from composite materials, which provide inherent damage containment capabilities. The composite material structure allows for built-in crack propagation resistance while maintaining the structural connection function.

Inventive Principle:

Principle #40Composite materials

4Strength

If multiple fasteners and metal parts are used for fuselage-to-wing joint, then structural connection is achieved, but weight of the aircraft increases

Engineering Contradiction:

Improvejoint connection strengthVSAvoidaircraft weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The monolithic upper chord assembly replaces multiple heavy fasteners and separate metal parts with a single integrated component. This merging maintains the necessary joint connection strength through the continuous material structure while significantly reducing the overall weight of the joint assembly.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The use of composite materials in the monolithic upper chord assembly provides high strength-to-weight ratio. The composite material construction maintains structural connection strength while using less material mass compared to traditional metal fastener assemblies.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11358703B2Monolithic wing to side body upper chord assembly for aircraft

Publication Date: 2022.06.14 THE BOEING CO

AI summary

A monolithic joint system for a fuselage to wing joint in an aircraft is provided. The joint system comprises a first vertical flange, a base plate, a second vertical flange, and damage containment features associated with at least one of these components. The first vertical flange is configured to connect to a fuselage section of the aircraft and the second vertical flange is configured to connect to a rib web of a wing, while the base plate attaches outboard wing to inboard wing box. The first vertical flange, the base plate, and the second vertical flange are formed from a continuous piece of material. The damage containment features are configured to slow propagation of an active crack tip in the joint system during operation of the aircraft. Thus, the illustrative embodiments provide a one-piece joint system for the fuselage to wing joint of an aircraft.