Composite Wing Edge Attachment with Co-Cured Shoulder
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for attaching fixed leading and trailing edges of composite aircraft wings are heavy, complex, and costly, often requiring additional processing steps and multiple parts, which can lead to weight, labor, and aerodynamic mis-fair issues.
Innovation Solution
A composite wing edge attachment system where a composite wing box skin panel with a constant thickness and ply count is co-cured with a ramp, forming an integral shoulder, allowing direct attachment of a wing edge skin panel, reducing the number of parts and weight, and enhancing aerodynamic smoothness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (splice straps, joggled panels, wiggle plates) are used to attach fixed edge skin panels, then joint integrity is achieved, but device complexity and weight increase
Solution Approach 1:
The patent merges the attachment function directly into the wing box skin panel by forming an integral shoulder through co-curing with tapered plies. This eliminates the need for separate splice straps, joggled panels, or wiggle plates, reducing device complexity while maintaining joint integrity through the integrated structural design.
Solution Approach 2:
The wing box skin panel serves multiple functions: it provides the primary structural skin and simultaneously creates the attachment shoulder for the fixed edge panel. The tapered plies within the skin panel perform both structural reinforcement and geometric shaping functions, eliminating the need for dedicated attachment components.
2Reliability
If traditional connection methods with multiple parts are used, then joint integrity is achieved, but weight increases
Solution Approach 1:
The attachment structure is merged with the wing box skin panel through co-curing, creating a single integrated component rather than separate parts. This eliminates the weight of additional splice straps, plates, and fasteners while maintaining joint integrity through the continuous composite structure.
Solution Approach 2:
The patent uses composite materials (tapered plies co-cured with the wing box skin) to create the attachment shoulder. This allows the structure to achieve both strength and weight efficiency by utilizing the high strength-to-weight ratio of composite materials in a tailored ply configuration.
3Reliability
If traditional connection methods are used, then joint integrity is achieved, but manufacturing complexity and processing steps increase
Solution Approach 1:
The attachment shoulder is formed preliminarily during the co-curing process of the wing box skin panel. The tapered plies are positioned and cured together with the main skin, creating the attachment geometry before the fixed edge panel is installed. This eliminates subsequent complex assembly steps and secondary bonding operations.
Solution Approach 2:
The manufacturing processes are merged by co-curing the wing box skin and attachment shoulder in a single operation. This eliminates multiple separate manufacturing steps, reduces processing complexity, and ensures inherent geometric accuracy through the integrated molding process.
4Strength
If thick wing box skin panels are used to provide structural strength, then strength is improved, but aerodynamic smoothness deteriorates at the wing edge
Solution Approach 1:
The patent applies local quality by using tapered plies only in the attachment region where structural reinforcement is needed. The plies taper from the thick wing box skin toward the thinner fixed edge panel, providing localized strength enhancement without affecting the overall aerodynamic contour. This allows the wing edge to maintain smooth aerodynamic lines while having reinforced attachment capability.
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 solution simplifies the attachment process, reduces weight and cost, and improves aerodynamic performance by eliminating the need for splice straps and secondary bonded fillers, while maintaining structural integrity and smooth surface profiles.
Implementation Method 1
a composite ramp, upon an outer surface of, and co-cured with, the composite wing box skin panel
Data Source
AI summary
A composite edge of an aircraft wing includes a composite wing box skin panel, attached to an outward wing spar in an attachment region, and a composite ramp, upon an outer surface of, and co-cured with, the composite wing box skin panel. The composite wing box skin panel has a proximal end and a distal end, with an overhanging edge, with substantially constant thickness and ply count in the attachment region. The composite ramp has a maximum ramp thickness at the distal end, the distal end being set back from the overhanging edge, defining a shoulder on the overhanging edge. A composite wing edge skin panel, having a thickness substantially equal to the maximum ramp thickness, is attached to the composite wing box skin panel at the shoulder and adjacent to the distal end of the ramp.