Thermoplastic Interlocking Grid for Flight Control Surfaces
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Solution Overview
Problem
Current aircraft flight control surface structures, such as GRID-LOCK, are inefficiently manufactured from aluminum billets, requiring lengthy processes and resulting in heavy, high-cost components, whereas thermoplastic materials offer lighter, tougher alternatives but are not effectively utilized in interlocking grid structures for flight control surfaces.
Innovation Solution
A thermoplastic interlocking grid structure method involving spars, ribs, and skins, where ribs interlock with spars at a perpendicular angle via notches and grooved structures, and are fastened using welding or adhesive bonding, allowing for automated fabrication and reduced material usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If aluminum billets are used to manufacture flight control surface structures, then structural strength is achieved, but manufacturing time increases and weight increases
Solution Approach 1:
The flight control surface structure is divided into discrete modular components (spars, ribs, skins) that can be independently manufactured and then assembled through interlocking mechanisms, replacing the monolithic aluminum billet approach and enabling parallel manufacturing processes
Solution Approach 2:
The patent employs composite material construction with thermoplastic spars, ribs, and skin panels that provide sufficient structural strength while enabling more efficient manufacturing processes compared to traditional aluminum billet machining
2Strength
If aluminum billets are used to manufacture flight control surface structures, then structural strength is achieved, but component weight increases
Solution Approach 1:
By segmenting the structure into thin skin panels and lightweight internal spars and ribs connected through interlocking mechanisms, the design achieves structural strength through the composite action of multiple lightweight components rather than a single heavy piece
Solution Approach 2:
The use of composite materials with high strength-to-weight ratio allows the structure to maintain required strength while significantly reducing component weight compared to solid aluminum construction
3Strength
If traditional aluminum-based structures are used, then structural integrity is maintained, but manufacturing complexity increases
Solution Approach 1:
Segmenting the structure into standardized modular components with consistent interlocking mechanisms simplifies manufacturing by enabling repetition of the same connection processes and facilitating automated assembly, despite the multi-component nature
Solution Approach 2:
The spars and ribs are pre-formed with integrated interlocking features (notches, grooves) during manufacturing, and skin panels are pre-drilled with alignment holes, enabling rapid assembly without complex field operations
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 method enables the efficient and lightweight fabrication of flight control surfaces using thermoplastic materials, reducing manufacturing time and weight while maintaining structural integrity, thus addressing the inefficiencies of traditional aluminum-based structures.
Implementation Method 1
The plurality of spars, the plurality of ribs, the first skin, and the second skin may include a thermoplastic material
Implementation Method 2
at least one of fillet welding, adhesive bonding, spot ultrasonic welding, or continuous ultrasonic welding
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A manufacturing method is provided. A first end of a set of spars (80) is coupled to a first skin (74) of a flight control surface. A set of ribs (90) is interlocked with the set of spars (80) and a first end of the set of ribs (90) is coupled to the first skin (74). A second skin (72) is coupled to a second end of the set of spars (80) and a second end of the set of ribs (90).