Monolithic Wing Spar With Strut For Stress Distribution
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Solution Overview
Problem
Current aircraft manufacturing techniques and designs face challenges in achieving optimal manufacturing efficiency, reliability, and performance, particularly in the structural components of aircraft wings, where stress distribution and redundancy are critical.
Innovation Solution
A monolithic spar structure for aircraft wings is introduced, comprising an upper chord, lower chord, and a web, with a distinct strut coupled between them, featuring pads with increased thickness and an angled orientation to enhance stress distribution and structural rigidity, potentially reducing manufacturing time and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a monolithic spar structure is used, then structural rigidity and stress distribution are improved, but manufacturing complexity increases
Solution Approach 1:
The patent combines the upper chord, lower chord, and web into a single monolithic spar structure that is manufactured as one integrated piece using 3D printing technology. This merging of components eliminates the need for separate parts and assembly operations, thereby improving structural rigidity and stress distribution while the additive manufacturing process manages the complexity through digital fabrication
2Productivity
If a monolithic spar structure with integrated components is used, then manufacturing time is reduced, but structural complexity increases
Solution Approach 1:
The patent utilizes 3D printing technology to manufacture the monolithic spar structure with varying geometries and thicknesses in different regions. The structure includes an upper chord, lower chord, and web with optimized dimensions that are printed as a single piece, reducing manufacturing time by eliminating assembly while managing structural complexity through precise geometric parameter control in the additive manufacturing process
3Stress or pressure
If pads with increased thickness are added to the monolithic structure, then stress distribution is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent incorporates pads with increased thickness at specific locations on the monolithic spar structure where stress concentration occurs. These locally thickened regions are integrated into the 3D printing process, allowing precise control of pad thickness and geometry through digital modeling. The local quality enhancement improves stress distribution while the additive manufacturing process maintains precision through layer-by-layer fabrication control
Data Source
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AI summary
A spar (610) for a wing for an aircraft includes a monolithic structure (650) and a strut (652). The monolithic structure (650) includes an upper chord (624), a lower chord (626), and a web (628) positioned between the upper chord (624) and the lower chord (626). The strut (652), distinct and separate from the monolithic structure (650), is coupled to the monolithic structure (650) between the upper chord (624) and the lower chord (626) and extends across the web (628).