Undulating Aircraft Gap Cover for Double-Curved Surfaces
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Solution Overview
Problem
Existing gap covers for aerial vehicles fail to provide a close fit on double-curved surfaces, are not cost-effective, and do not adequately reduce radar detectability and lightning vulnerability.
Innovation Solution
A cover with an undulating shape and flexible section that generates intrinsic biasing force for a close fit, made from conductive materials, which can be easily attached and detached, ensuring a smooth transition and reduced radar echo by eliminating gaps between double-curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a plain cover is used to cover the gap, then the manufacturing is simple and cost-effective, but the cover cannot provide a close fit on double-curved surfaces
Solution Approach 1:
The cover employs an undulating shape with wave crests and troughs that correspond to the double-curved geometry of the aircraft skin. This curved configuration allows the cover to conform to the complex surface geometry, achieving a close fit that eliminates gaps while maintaining structural integrity across varying curvatures.
Solution Approach 2:
The cover utilizes changes in the physical state of the flexible section, transitioning from an un-loaded state with an undulating shape to a loaded state where the undulation provides biasing force. This parameter change enables the cover to adapt to the double-curved surface while maintaining manufacturing simplicity through a single-piece construction.
2Object-affected harmful factors
If gaps are left between structural portions, then the cover design is simpler, but radar detectability increases
Solution Approach 1:
The undulating shape with wave crests and troughs allows the cover to conform to double-curved surfaces, eliminating gaps between the cover and the aircraft skin. This continuous coverage prevents radar waves from detecting gaps while maintaining a practical design that can be manufactured as a single piece.
3Adaptability or versatility
If a rigid cover is used, then the structure is simpler, but the cover cannot accommodate movable control surfaces
Solution Approach 1:
The cover employs a flexible section with undulating geometry that can deform and adapt to the movement of control surfaces while maintaining structural integrity. The wave crests and troughs provide the necessary flexibility to accommodate movable parts without requiring complex mechanical linkages or compromising the cover's strength.
4Weight of moving object
If the cover is made lightweight, then the weight constraint is satisfied, but the material options are limited
Solution Approach 1:
The cover is constructed as a lightweight flexible shell with an undulating shape that can be formed from thin-walled materials. This approach achieves the required weight reduction while maintaining structural integrity and radar reflectivity through the geometric configuration rather than material thickness, allowing for cost-effective manufacturing using conventional aerospace materials.
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
The cover achieves a close fit on double-curved surfaces, reduces radar detectability, and enhances lightning protection while being lightweight and cost-effective to produce, allowing for easy replacement and installation.
Implementation Method 1
The flexible section (11) includes an abutment portion (13) which, in an un-loaded state, forms an undulating shape U. The undulating shape U presents troughs (15) and crests (17), which extend along a double curved plane.
Implementation Method 2
The material of the gap filler is made with electrical conductance for rendering the aircraft less detectable by radar and more capable of discharging lightning.
Data Source
Figure 1a~2
Figure 3a~3b
Figure 4a~4d
AI summary
The present invention regards a cover for covering a gap (2) between a first structural portion (3, 3 ') and a second structural portion (5, 5') of an aerial vehicle (29, 41 ), the cover (1, 25) comprises a first attachment section (9), attachable to the first structural portion (3, 3'), and a second flexible section (11) for covering the gap (2), the second flexible section (11) includes an abutment portion ( 13) for abutting against the second structural portion (5, 5 ') in an operating state. The abutment portion (13) in an unloaded state forms an undulating shape (U) having troughs (15) and crests (17) extending along a curved plane, the curvature of which essentially corresponds with the curvature (C) of the second structural portion's (5, 5') surface (6, 27), wherein the troughs (15) are provided for engagement with said surface (6, 27) in said operating state in such way that they tend to be flatten out and propagate over said surface (6, 27) pressing down neighbouring crests ( 17) towards said surface (6, 27) for providing a close fit between the cover (1, 25) and the second structural portion (5, 5').