Segmented Airfoil Structure for Variable-Chord Manufacturing
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Solution Overview
Problem
Existing airfoil manufacturing methods, such as extrusion and pultrusion, are limited by maximum dimensions and constant cross-sections, restricting the ability to vary the chord and adapt to different needs, leading to complex and costly manufacturing processes.
Innovation Solution
An airfoil design comprising a front and rear section with varying thickness, assembled to include a central portion of constant thickness, allowing for flexible adjustment of the chord length, manufactured through extrusion or pultrusion processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the chord of the airfoil is reduced to adapt to different wing spans, then the airfoil can be used across different wing sizes, but the thickness must be proportionally reduced which limits structural performance
Solution Approach 1:
The airfoil is divided into three distinct segments along the chord: a front portion with increasing thickness, a central portion with constant maximum thickness, and a rear portion with decreasing thickness. This segmentation allows the central portion to maintain optimal thickness for structural strength while the overall chord length can be scaled to fit different wing spans, thus resolving the contradiction between adaptability and strength.
2Reliability
If the chord and thickness of the airfoil are allowed to vary to optimize performance, then aerodynamic efficiency improves, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The airfoil design applies local quality by giving different portions of the airfoil different thickness characteristics optimized for their specific functions: the front portion builds up thickness to accommodate leading edge structural requirements, the central portion maintains constant maximum thickness for optimal aerodynamic performance and structural strength, and the rear portion tapers to the trailing edge. This localized optimization achieves high aerodynamic efficiency while maintaining manufacturability through clear, distinct geometric zones.
3Ease of manufacture
If extrusion and pultrusion processes are used to manufacture airfoils, then production cost is reduced, but the airfoil must have constant cross-section which limits design flexibility
Solution Approach 1:
The airfoil is segmented into three portions that can be manufactured using extrusion or pultrusion processes and then assembled together. The front portion, central portion, and rear portion are produced as separate components with constant cross-sections suitable for extrusion/pultrusion, then joined to create the complete variable-chord airfoil. This segmentation enables cost-effective manufacturing while achieving the desired chord variation and thickness distribution.
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
Enables simple and economical production of airfoils with variable chord lengths, maintaining performance and adaptability to different applications, reducing manufacturing complexity and costs.
Implementation Method 1
One of the most efficient methods is to obtain the fluid-dynamic surface 54 of the blade 56 by extrusion/pultrusion
Implementation Method 2
Pultrusion is an industrial process that essentially consists of forcing, by traction, the components of a composite material (fibres and matrix) to pass through a die that reproduces the external shape of the piece to be obtained
Data Source
AI summary
An airfoil including a front leading edge, a rear trailing edge, a mean line and a thickness. The airfoil further includes: a front portion in which the thickness increases from the leading edge backwards up to a maximum thickness, and a rear portion in which the thickness increases from the trailing edge forwards up to the maximum thickness. The airfoil further includes a central portion placed between the front portion and the rear portion, in which the thickness is constant and equal to the maximum thickness. The airfoil also includes at least one assembled front section and rear section. The front portion is defined by the front section and the rear portion is defined by the rear section. The embodiments further concern a fluid-dynamic surface including two airfoils and a method for defining such an airfoil.