Solid Insert Joining Airframe Members
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Solution Overview
Problem
The assembly of torque box structures in conventional tiltrotor aircraft wings is complex due to tight tolerances and limited access, making the installation of fasteners and internal support members difficult, and the thickness of stringers reduces space for fuel and internal systems.
Innovation Solution
The use of large cell core stiffened panels with solid inserts provides a lightweight, high-stiffness structure by structurally bonding a large cell core and solid inserts between skins, offering improved joining locations and reduced complexity in assembly, while eliminating the need for conventional stringers, thus enhancing fuel bay clearance and structural support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional stringers and multiple internal support members are used to provide structural strength, then the airframe achieves sufficient stiffness and load-bearing capacity, but the space available for fuel and internal systems is reduced
Solution Approach 1:
The patent extracts and eliminates the conventional stringer system from the airframe structure. By using a solid insert joined directly to the skin members, the patent removes the need for multiple internal support members and stringers, thereby increasing fuel bay space while maintaining structural strength through the solid insert design
Solution Approach 2:
The solid insert serves multiple functions simultaneously: it provides structural strength at load points, creates joining locations for coupling airframe members, and increases fuel bay clearance. This multi-functional design replaces the need for separate stringers and support members
2Reliability
If numerous fasteners and internal support members are installed in the torque box structure, then the structural members are adequately assembled and supported, but the assembly process becomes complex and time-consuming due to limited access
Solution Approach 1:
The patent extracts and removes the complex system of numerous fasteners and multiple internal support members from the torque box structure. By using solid inserts with integrated joining locations, the patent simplifies the assembly process while maintaining assembly reliability through the robust solid insert-to-skin member connections
Solution Approach 2:
The solid insert serves as a universal component that combines multiple functions: it provides structural support, creates joining locations for fasteners, and simplifies the assembly process. This multi-functional design eliminates the need for separate internal support members and reduces the number of fastening operations required
3Stability of the object's composition
If conventional stringers with reinforcement strips are used to support the skins, then the skins are protected against buckling and maintain their shape, but the overall structure becomes heavier and more complex
Solution Approach 1:
The patent extracts and eliminates the conventional stringer system with reinforcement strips from the airframe structure. By using solid inserts joined directly to the skin members, the patent reduces structure weight while maintaining skin stability through the solid insert design that provides support at critical load points
Solution Approach 2:
The patent employs composite materials for the solid inserts and skin members, which provide high strength-to-weight ratio. This allows the structure to maintain skin stability and resist buckling while being lighter than conventional aluminum stringer systems
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 solution simplifies the assembly process, reduces weight, and increases internal space by providing a strong, lightweight structure with improved stiffness and torsional support, while minimizing the complexity and cost of manufacturing and installation.
Implementation Method 1
The large cell core and the solid insert may be structurally bonded between the first and second skins
Data Source
AI summary
An airframe assembly for an aircraft includes a first airframe member having first and second skins with a large cell core and a solid insert joined therebetween. The solid insert has a side surface at least a portion of which is adjacent to the large cell core. The first airframe member has a first set of openings extending through the first skin, the solid insert and the second skin. The airframe assembly also includes a second airframe member having a second set of openings operable to be aligned with the first set of openings of the first airframe member. Each of a plurality of fasteners extends through one of the openings of the first set of openings and one of the openings of the second set of openings securably coupling the first airframe member to the second airframe member.