Trailing-Edge Unit With Integrated Protrusions for Simpler Manufacturing
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Solution Overview
Problem
Conventional manufacturing processes for aerodynamic components like trailing-edge units in aircraft flaps are complex and require extensive preparation, vacuum foils, and autoclave bonding, making them sophisticated and time-consuming.
Innovation Solution
A trailing-edge unit design that integrates protrusions into a single-piece sheet material layer, eliminating the need for a honeycomb core and reducing the complexity of manufacturing by avoiding water-tight sealings and autoclave bonding, while still accommodating structural loads through a core structure supported by protrusions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a honeycomb core with metal-metal bonding is used in the trailing-edge unit, then structural integrity and water-tightness are improved, but manufacturing complexity and process time increase significantly
Solution Approach 1:
The patent removes the honeycomb core from the trailing-edge unit construction. Instead of using a separate honeycomb core between skin elements, the invention uses protrusions integrated directly into the skin elements themselves, eliminating the need for complex bonding processes while maintaining structural integrity
Solution Approach 2:
The patent combines the functions of the skin element and the structural support into a single integrated component. The protrusions are formed as part of the skin element itself, merging what were previously separate components (skin + honeycomb core) into one piece, thereby simplifying manufacturing
2Reliability
If extensive preparation and autoclave bonding are used for water-tight assembly, then sealing reliability is improved, but manufacturing time and process sophistication increase
Solution Approach 1:
The patent eliminates the need for vacuum foils, clean room atmosphere, and autoclave bonding processes by removing the separate honeycomb core structure that required water-tight sealing. The integrated protrusion design inherently provides structural continuity without requiring additional sealing measures
Solution Approach 2:
The protrusions are formed directly as part of the skin element through stamping or deep drawing, making the structural support function self-contained within the skin element itself, eliminating the need for separate assembly and bonding operations
3Ease of manufacture
If a single-piece structure with protrusions is used, then manufacturing simplicity is improved, but structural load capacity must be maintained
Solution Approach 1:
The patent applies local quality by creating protrusions with specific geometries (such as hollow cylindrical shapes) at specific locations on the skin element. These localized structural features provide enhanced load-bearing capacity where needed, while the rest of the skin element maintains its primary aerodynamic function
Solution Approach 2:
The patent utilizes the skin element material itself to create the protrusions, forming a composite-like structure where the same material serves multiple functions (aerodynamic surface and structural support). The protrusions can be formed with hollow interiors or solid cores depending on the required strength characteristics
Data Source
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AI summary
The invention relates to a trailing-edge unit (1) comprising a first skin element (10) having an inner surface (11) and an outer surface (12) as well as a second skin element (20) having an inner surface (21) and an outer surface (22). It also comprises a core structure (30) arranged between the first and second skin elements (10, 20) and configured to support the first and second skin elements (10, 20). The core structure (30) comprises a first core element (31) having a first sheet material layer (33) and first protrusions (35), wherein the first sheet material layer (33) and the first protrusions (35) are formed as a single-piece structure. The first sheet material layer (33) is connected to the inner surface (11) of the first skin element (10) and the first protrusions (35) extend towards the second skin element (20). The invention also relates to a method for manufacturing a trailing-edge unit (1).