Stringer Edge Glow Discharge Prevention in Composite Manufacturing
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Solution Overview
Problem
Current manufacturing methods for reinforcing structures, such as those used in aircraft wings, increase the manufacturing process and part count when attempting to prevent edge glow discharge by sealing fiber exposure surfaces, either through additional curing processes or applying seal materials.
Innovation Solution
A method involving the use of an insulation protection material, comprising a composite of resin and insulative fibers, is applied to cover at least a part of the fiber exposure surface on the stringer, which is then cured simultaneously with the skin, preventing edge glow discharge without adding new processes or increasing part complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a thermosetting resin layer is applied to seal the fiber exposure surface, then edge glow discharge is prevented, but an additional curing process is required increasing manufacturing complexity
Solution Approach 1:
The patent merges the sealing function with the existing structural reinforcement function by using the stringer itself as the seal structure. The stringer is designed to protrude beyond the skin surface, and this protruding portion naturally covers the fiber exposure surface, eliminating the need for a separate thermosetting resin sealing layer and its associated curing process.
Solution Approach 2:
The patent extracts the sealing function from the traditional thermosetting resin layer approach and integrates it into the stringer structure itself. By making the stringer protrude beyond the skin, the sealing action is performed by the stringer's own geometry rather than by a separate material layer.
2Reliability
If a seal material such as gum material is applied to the fiber exposure surface after bonding, then edge glow discharge is prevented, but the manufacturing process increases and the number of parts increases
Solution Approach 1:
The patent combines the sealing function with the stringer structure by designing the stringer to protrude beyond the skin surface. This protruding portion serves dual purposes: structural reinforcement and sealing of the fiber exposure surface, thereby eliminating the need for separate seal materials and reducing the total number of parts.
Solution Approach 2:
The stringer is designed to perform multiple functions: it provides structural reinforcement to the skin and simultaneously seals the fiber exposure surface to prevent edge glow discharge. This multi-functionality eliminates the need for separate sealing components.
3Manufacturing precision
If the stringer is processed to adjust its size, then fit is improved, but the fiber component is exposed forming a fiber exposure surface that causes edge glow discharge
Solution Approach 1:
The patent applies preliminary anti-action by designing the stringer with a protruding portion that extends beyond the skin surface before bonding. This protruding structure pre-empts the fiber exposure problem by covering the fiber exposure surface that would otherwise be created during size adjustment processing, thereby preventing edge glow discharge before it can occur.
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 effectively prevents edge glow discharge without increasing the manufacturing process complexity, maintains structural strength, and avoids the need for specialized sealing techniques, ensuring the reinforcing structure's integrity while minimizing weight and process additions.
Implementation Method 1
the insulation protection material includes a composite material having a resin component and an insulative fiber component
Implementation Method 2
When the fiber exposure surface exists, an edge glow discharge sometimes occurs with the applied current or voltage
Implementation Method 3
the skin is cured by use of heat and pressure and the stringer is bonded with the skin as a unitary body
Implementation Method 4
a cured stringer is arranged on an uncured skin through adhesive
Data Source
AI summary
A manufacturing method of a reinforcing structure includes: preparing a stringer having a fiber exposure surface; arranging an insulation protection material to cover at least a part of the fiber exposure surface; arranging the stringer on a skin having an uncured resin component; and curing the skin after the arranging the stringer. The insulation protection material includes a composite material having a resin component and an insulative fiber component. The curing the skin includes curing the skin and the insulation protection material at the same time. In the manufacturing method of a reinforcing structure, an edge glow discharge can be prevented without increasing a manufacturing process.