Removable Artificial Ice Components for Aircraft Certification

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Solution Overview

Problem

Current methods for aircraft icing certification are time-consuming and expensive due to the need for constructing and attaching artificial ice shapes on the wing, which often result in damage to the aircraft during removal.

Innovation Solution

The development of artificial ice components with inner surfaces contoured to match aircraft surfaces and outer surfaces meeting FAA certification requirements, manufactured prior to attachment using methods like additive layer manufacturing, and attached using a double-sided adhesive system for easy removal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If artificial ice shapes are constructed on the wing using fiberglass and resin and mechanically secured with bolts, then the ice shapes can be securely attached for flight testing, but the removal process causes damage to the aircraft surfaces and increases cost

Engineering Contradiction:

Improvesecure attachment of ice shapesVSAvoiddamage to aircraft surfaces

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a removable mounting structure as an intermediary between the artificial ice shape and the aircraft wing. This mounting structure includes a base plate that attaches to the wing surface and a body portion that holds the ice shape material, allowing secure attachment during testing while enabling clean removal without damaging the aircraft surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mounting structure is divided into separable components: a base plate portion that interfaces with the aircraft wing and a body portion that contains the ice shape material. This segmentation allows the ice shape to be removed as a complete unit from the wing, preventing damage to the aircraft surfaces while maintaining secure attachment during flight testing.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If artificial ice shapes are constructed and attached to the wing for certification testing, then FAA icing certification requirements can be met, but the process becomes time-consuming and expensive

Engineering Contradiction:

Improvecompliance with FAA certification requirementsVSAvoidcertification process duration

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The mounting structure is designed and prepared in advance before the actual flight testing begins. The base plate and body portion are pre-assembled, and the artificial ice shape is pre-formed to exact specifications, allowing for rapid installation on the aircraft wing and reducing the overall certification timeline.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs additive layer manufacturing (3D printing) to create the mounting structure and artificial ice shapes with precise geometric parameters and surface roughness characteristics that meet FAA certification requirements. This manufacturing method allows for rapid production of custom-fitted components without traditional tooling, significantly reducing lead time.

Inventive Principle:

Principle #35Parameter changes

3Ease of repair

If artificial ice shapes are removed after certification flight, then the aircraft can be returned to service, but the removal process damages the wing and tail surfaces

Engineering Contradiction:

Improvereturn to serviceVSAvoidsurface damage

Core Design Contradiction:

Ease of repairVSObject-affected harmful factors

Solution Approach 1:

The removable mounting structure serves as an intermediary that protects the aircraft surfaces during the attachment and removal processes. The base plate distributes attachment forces over a larger area and the modular design allows the entire ice shape assembly to be removed as one unit, preventing damage to the wing and tail surfaces while enabling quick return to service.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 reduces the time and cost of certification by allowing rapid installation and removal of artificial ice shapes without damaging the aircraft, while ensuring compliance with FAA icing certification requirements.

Implementation Method 1

attaching the set of artificial ice sections to the surface of the aircraft via a double-sided adhesive system

Methodology Applied

Scientific EffectAdhesive bonding: Adhesive

Implementation Method 2

removing the ice sections from the aircraft by disrupting the adhesive system

Methodology Applied

Scientific EffectMechanical disruption of adhesive bonds: Mechanical Force

Data Source

PatentUS10337952B2Systems and methods for icing flight tests

Publication Date: 2019.07.02 THE BOEING CO

AI summary

Systems and methods for the manufacture and use of artificial ice shapes for aircraft certification, including methods of manufacturing artificial ice shapes, artificial ice component systems for attachment to aircraft, methods of flight testing aircraft having artificial ice sections attached thereto, and artificial ice testing systems.