Aircraft Spoiler Core Segmentation and Infusion
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Solution Overview
Problem
Existing control surface elements in aerospace face issues with water ingress, impact protection, and complex, costly production methods, particularly due to honeycomb core structures and separate process steps for outer skins and reinforcing ribs, which hinder weight savings and effective power transmission.
Innovation Solution
A control surface element design featuring reinforcing ribs positioned between core segments, allowing for an infusion process that integrates the formation of upper and lower outer skins and reinforcing ribs, with core segments extending to prevent water ingress and enhance impact protection by filling gaps between skin elements, and using fiber composite materials for improved structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a honeycomb core structure is used in control surfaces, then structural support is provided, but water ingress susceptibility increases and impact protection is inconsistent
Solution Approach 1:
The core element is divided into multiple core segments arranged side-by-side, with each segment having a solid interior without internal cavities. This segmentation eliminates the honeycomb structure's internal channels that allow water ingress while maintaining structural support through the collective arrangement of solid segments.
Solution Approach 2:
The core segments are positioned such that their lateral surfaces are in contact with reinforcing ribs at specific locations, providing localized structural support where needed. The gaps between core segments are filled with sealing material to prevent water ingress at interfaces, combining structural function with water protection.
2Strength
If outer skins and reinforcing ribs are produced in separate process steps using prepregs, then structural integrity is achieved, but production complexity and cost increase
Solution Approach 1:
The method combines the formation of upper outer skin, lower outer skin, and reinforcing ribs into a single infusion process step. Liquid plastic is introduced through feed lines and impregnates fiber composite materials arranged on the core segments, creating all structural components simultaneously and eliminating separate prepreg processing steps.
Solution Approach 2:
The infusion process serves multiple functions simultaneously: it forms the upper and lower outer skins, creates the reinforcing ribs, and bonds all components together into an integrated structure. This single process replaces multiple specialized manufacturing steps, reducing complexity while maintaining structural integrity.
3Ease of manufacture
If adhesive bonds are used to join upper and lower skins, then assembly is achieved, but weak points susceptible to impact damage are created
Solution Approach 1:
The upper and lower outer skins are joined to the core segments and reinforcing ribs through direct mechanical bonding via the infusion process, eliminating separate adhesive bonding steps. The liquid plastic penetrates fiber materials to create integral bonds, removing adhesive layers that would create weak points under impact loads.
4Weight of moving object
If cavities are present between stiffening ribs, then weight reduction is achieved, but water ingress susceptibility increases
Solution Approach 1:
The gaps between core segments are selectively filled with sealing material only at locations where water ingress could occur, while maintaining open spaces elsewhere for weight reduction. The sealing material is applied locally at the interfaces between core segments and reinforcing ribs, preventing water ingress without requiring complete solidification of the entire core structure.
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 design simplifies production, enhances water resistance and impact protection, eliminates structural weaknesses, and ensures effective power transmission while achieving weight savings and compliance with air traffic admission requirements.
Implementation Method 1
a plastic in a liquid state is introduced through feed lines (30) into the infusion chamber (25), with the liquid plastic impregnating the fiber composite material to form the upper and lower outer skin elements (2; 3) and the reinforcing rib (8)
Data Source
Figure 1
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AI summary
A control surface element (1) for an aircraft, more particularly a spoiler, comprising an upper outer skin element (2) that has an outer air flow face (4); comprising a lower outer skin element (3); comprising at least one reinforcement rib (8); and comprising a core element (9) made of a foam material; wherein the reinforcement rib (8) is positioned between two core segments (10) of the core element (9).