Tapered Edge Panel for Aerodynamic Lap Splice
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Solution Overview
Problem
Existing aircraft aerodynamic surfaces often form gaps due to mechanical coupling, leading to increased aerodynamic disturbance, drag, and decreased lift, which existing techniques attempt to address with splice straps and fillers but require additional parts and steps.
Innovation Solution
The aircraft structure incorporates an edge panel with a tapered second edge panel portion and a skin with specific thickness and bend configurations, allowing for a smooth aerodynamic contour and simplified installation without the need for fillers or extra parts, using a multi-ply composite material with a ply drop offset to reduce thickness and enhance fitment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If splice straps and fillers are used to decrease gaps between panels, then aerodynamic performance is improved, but device complexity and manufacturing steps increase
Solution Approach 1:
The patent removes the need for separate splice straps and fillers by integrating the gap-closing function directly into the panel structure itself. The second panel is designed with a tapered thickness that allows it to fit tightly against the first panel, eliminating the need for additional gap-closing components while maintaining aerodynamic performance.
Solution Approach 2:
The patent combines multiple functions into the panel structure: the second panel simultaneously serves as both the aerodynamic surface and the gap-closing element. The tapered portion of the second panel integrates the structural, aerodynamic, and sealing functions that would otherwise require separate components.
2Object-affected harmful factors
If splice straps and fillers are used to eliminate gaps, then aerodynamic performance is improved, but manufacturing time and steps increase
Solution Approach 1:
The gap-closing capability is built into the panel design during manufacturing. The tapered thickness of the second panel is pre-configured to achieve the desired fit, eliminating the need for time-consuming installation steps of separate splice straps and fillers during assembly.
Solution Approach 2:
The second panel is designed to self-align and self-fit against the first panel through its tapered geometry. The panel's own structure provides the gap-closing function without requiring additional adjustment or installation of separate components, reducing manufacturing time.
3Object-affected harmful factors
If panel thickness is reduced to eliminate gaps, then aerodynamic performance is improved, but structural strength may be compromised
Solution Approach 1:
The panel employs varying thickness locally: the second panel has a tapered thickness with a thicker portion at the leading edge (providing structural strength) and a thinner portion at the trailing edge (reducing gap size). This local variation in thickness optimizes both structural integrity and aerodynamic performance.
Solution Approach 2:
The patent utilizes composite material construction that allows for complex thickness variations and tapered geometries while maintaining structural strength. The composite structure enables the tapered design that reduces gaps without compromising the panel's load-bearing capacity.
Data Source
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AI summary
Systems and methods for an aerodynamic device with a lap splice that includes an edge panel is described herein. In edge panel can include a tapered section. A portion of a skin of the aerodynamic device can be disposed below the tapered section. One or both of the edge panel or the skin can be composite. The tapered section of the edge panel can be formed by decreasing the ply thickness of the edge panel.