Titanium-End Composite Panels for Vented Skin Assembly

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Solution Overview

Problem

Manufacturing large composite skins as a single large continuous piece poses challenges in maintaining timelines, reducing costs, and addressing inconsistencies due to traditional fasteners, while manufacturing composite skins as multiple discrete portions presents difficulties in joining and evacuating air and volatiles during fabrication.

Innovation Solution

A composite structure design incorporating titanium ends and composite skins joined between them, allowing for escape paths for air and volatiles, and using one-sided fasteners for easy access and maintenance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If large composite skins are manufactured as a single large continuous piece, then structural integrity is improved, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The composite skin is divided into multiple discrete panels that are joined together using titanium ends. Each panel can be manufactured separately with consistent quality control, then assembled into a large continuous structure. The titanium ends serve as standardized joining elements that maintain structural integrity while enabling modular manufacturing.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If traditional fasteners are used to join composite panels, then assembly is simplified, but inconsistency points are introduced in the composite skin

Engineering Contradiction:

Improveassembly simplicityVSAvoidconsistency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The joining system uses a composite of titanium ends bonded to composite panels. The titanium ends are bonded to the composite panels using adhesive bonding, creating a hybrid metal-composite joint that maintains consistency throughout the structure. This eliminates traditional mechanical fasteners that would create inconsistency points, while still enabling straightforward assembly.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If composite skins are manufactured as multiple discrete portions, then manufacturing flexibility is improved, but joining difficulty increases

Engineering Contradiction:

Improvemanufacturing flexibilityVSAvoidjoining difficulty

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The titanium ends serve as intermediary elements between composite panels. These titanium ends provide standardized bonding surfaces that simplify the joining process. The intermediary titanium components enable consistent adhesive bonding between panels, reducing joining difficulty while maintaining manufacturing flexibility.

Inventive Principle:

Principle #24Intermediary (Mediator)

4Strength

If large titanium parts are used, then structural strength is improved, but weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The structure uses hybrid titanium-composite construction where titanium ends are bonded to composite panels. The composite panels replace large titanium sections, significantly reducing weight while maintaining structural strength. The titanium ends provide necessary strength at critical joining points, while the composite panels provide lightweight coverage over large areas.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentEP4663536A1Composite panels with titanium ends

Publication Date: 2025.12.17 THE BOEING CO

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AI summary

A composite structure and methods of forming are presented. A composite structure comprises: structural supports and a structural skin formed by a plurality of composite panels fastened to the structural supports. Each composite panel of the plurality of composite panels comprises a first titanium end; a second titanium end; and a composite skin joined to and extending between the first titanium end and the second titanium end.