Multi-box Wing Spar Composite Layup for Structural Integrity
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Solution Overview
Problem
Conventional aircraft wing construction is time-consuming, labor-intensive, and results in a complex structure with multiple parts, increasing weight and reducing the structural integrity of composite materials due to multiple breaks in fibers.
Innovation Solution
The use of multi-box wing spars formed using forming mandrels with composite materials applied and compressed to create a contiguous, rigid structure with minimal fiber bends, eliminating the need for a traditional wing box and reducing material breaks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional wing construction methods are used with multiple parts and traditional wing box structures, then the wing can be assembled using standard procedures, but the weight increases and structural integrity decreases due to multiple fiber breaks
Solution Approach 1:
The patent merges multiple separate structural components (spars, ribs, stringers, and wing box) into a single integrated multi-box spar structure. This consolidation eliminates the need for traditional wing boxes and multiple discrete parts, directly reducing weight while maintaining structural integrity through continuous composite fiber construction throughout the entire wing assembly.
Solution Approach 2:
The invention employs composite materials with continuous fibers that extend throughout the multi-box spar structure without breaks. This use of continuous composite materials provides superior strength-to-weight ratio compared to conventional metal structures with multiple joints and fasteners, directly addressing both the strength improvement and weight reduction goals.
2Productivity
If conventional wing construction with multiple parts is used, then the wing can be assembled using standard procedures, but the construction process becomes time-consuming and labor-intensive
Solution Approach 1:
The patent combines multiple discrete components into a single integrated multi-box spar structure that can be manufactured as one piece or pre-assembled unit. This merging of components dramatically reduces the number of parts that need to be individually assembled, thereby reducing construction time and labor requirements while simplifying the overall device complexity.
Solution Approach 2:
The multi-box spar structure is designed to be manufactured and prepared in advance as a complete integrated unit, with all structural features (spars, ribs, stringers) already incorporated. This preliminary action of pre-manufacturing the complete structure eliminates the need for time-consuming on-site assembly of multiple separate parts during wing construction.
3Strength
If traditional wing box structures are used, then the wing can provide necessary support, but the structure becomes more complex and heavier
Solution Approach 1:
The patent integrates the functions of multiple structural elements (spars, ribs, stringers, and wing box) into a single multi-box spar structure. This merging provides all necessary structural support functions that were previously distributed across multiple separate components, thereby reducing structural complexity while maintaining or improving strength characteristics.
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 method simplifies the construction process, enhances structural rigidity by maintaining straight fibers, and reduces material waste, resulting in a lighter and stronger aircraft wing.
Implementation Method 1
a compression apparatus for compressing the several mandrels together to cure layers of composite material on the mandrels
Data Source
AI summary
Apparatus and systems provide for the construction of wing sections having a plurality of wing spars abutted against each other to form a contiguous multi-box wing spar layup. An aircraft wing includes a plurality of wing spars configured to be attached to an aircraft fuselage, an upper wing surface, and a lower wing surface. The plurality of wing spars are in a multi-box wing spar layup. The plurality of wing spars, the upper wing surface, and the lower wing surface are composite layers having continuous fibers.