Variable Web Height Composite Aircraft Beam
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Solution Overview
Problem
Current composite aircraft structures require multiple components of different materials to achieve complex geometries, leading to increased costs, maintenance, and reduced structural rigidity due to the need for constant web heights in beam manufacturing.
Innovation Solution
A variable web height laminate composite structural beam is introduced, featuring a first flange and a second flange separated by different distances along the web, allowing for a single component to replace multiple materials and accommodate complex geometries, thereby enhancing structural rigidity and reducing maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple components of different materials are used to achieve complex geometries, then the structural adaptability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges multiple separate components (composite beam, titanium shear-ties, aluminum plates) into a single monolithic composite structure. This integration eliminates the need for multiple different materials and components, reducing assembly complexity while maintaining the ability to achieve complex geometries through the single composite structure's design
Solution Approach 2:
The monolithic composite structure serves multiple functions that previously required separate components. A single composite beam provides both structural support and geometric complexity, eliminating the need for additional titanium shear-ties and aluminum plates, thereby reducing overall device complexity while maintaining structural adaptability
2Adaptability or versatility
If multiple components are assembled together, then the structural adaptability is improved, but the manufacturing precision and tolerance control deteriorate
Solution Approach 1:
By combining multiple components into a single monolithic composite structure, the patent eliminates multiple assembly interfaces and joints. This reduces the cumulative tolerance stack-up that occurs when assembling multiple parts, thereby improving manufacturing precision while maintaining structural adaptability through the integrated design
3Adaptability or versatility
If multiple components and joints are used, then the structural adaptability is improved, but the reliability deteriorates due to increased points of failure
Solution Approach 1:
The patent eliminates multiple joints, connections, and interfaces by using a monolithic composite structure. This reduction in connection points directly reduces the number of potential failure points, thereby improving reliability while maintaining structural adaptability through the integrated composite design
4Ease of manufacture
If constant web heights are used in composite beams, then the manufacturing ease is improved, but the adaptability to complex geometries deteriorates
Solution Approach 1:
The patent applies local quality by allowing the web height of the composite beam to vary at different locations along its length. This enables the structure to achieve complex geometries required for applications like the nose wheel well assembly, while the composite manufacturing process remains adaptable to these variable dimensions through tailored fiber placement and curing
Data Source
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AI summary
Systems and methods are provided for a variable web height aircraft composite structural beam. The variable web height aircraft composite structural beam includes a variable height web (320), a first flange (314) located on an outer portion of the web, and a second flange (312) located on an inner portion of the web. The variable height web is a first height in a first portion (316) of the variable web height aircraft composite structural beam and a second height in a second portion thereof. The variable web height aircraft composite structural beam is a structural beam of an aircraft.