Seal Member for Aircraft Wing Gap Sealing
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Solution Overview
Problem
Conventional aerospace sealants struggle to effectively seal gaps in aircraft wing assemblies with fibre-reinforced composite spars due to the larger radius corners, leading to increased leakage drag and reduced performance at high speeds.
Innovation Solution
A seal member, such as a plectrum-shaped plastics component, is attached to the wing rib and wing cover, covering the gap and combined with aerospace grade sealant to prevent air flow between compartments, reducing the area to be sealed and enhancing structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a composite spar with a radius corner is used, then the manufacturing difficulty is reduced, but the gap size increases making it difficult to seal
Solution Approach 1:
The sealing solution is divided into two distinct segments: a seal member (such as a gusset plate or butt-strap) that covers the majority of the gap, and sealant that fills the remaining space. This segmentation allows each component to address specific aspects of the sealing challenge, with the seal member handling the bulk coverage and the sealant providing the final seal.
Solution Approach 2:
A seal member is introduced as an intermediary component between the spar and the wing panel/rib. This intermediary element bridges the gap created by the radius corner, providing a surface for sealant attachment and creating a more manageable sealing geometry that converts a difficult large-gap seal into a smaller, more controllable seal joint.
2Device complexity
If conventional aerospace sealant is used alone, then the sealing process is simple, but the seal effectiveness is insufficient for large gaps
Solution Approach 1:
The sealing system uses a composite approach combining two different materials with complementary properties: a seal member (which can be metal, composite, or plastic) that provides structural coverage and geometry control, and aerospace-grade sealant that provides flexible sealing and adhesion. This composite sealing system addresses both the structural and sealing requirements that neither material could satisfy alone.
Solution Approach 2:
The solution transitions from a two-dimensional sealant-only approach to a three-dimensional composite sealing system. The seal member adds a structural dimension that covers the gap area, while the sealant provides the sealing dimension in the remaining space, creating a multi-layered sealing architecture that is more effective than a single-layer approach.
3Ease of manufacture
If a large radius corner is used in the composite spar, then manufacturing is easier, but the gap area increases requiring more sealant
Solution Approach 1:
The seal member is extracted from the gap area, physically removing the need for sealant to cover the entire gap. By placing the seal member over the gap, the sealing function is partially extracted and transferred to this dedicated component, leaving only a reduced area that requires sealant application.
Solution Approach 2:
The seal member provides partial sealing action by covering the majority of the gap area, while the sealant provides the remaining sealing action in the reduced space. This partial action approach divides the sealing task between two components, with the seal member handling the bulk coverage and the sealant handling the precision sealing.
Data Source
AI summary
A wing assembly 2 for an aircraft 1 comprising a spar 3, a wing cover 4 and a rib 5; wherein the spar has a web portion 3a and a flange portion 3b joined by a radius corner 3c; wherein a gap 6 is formed at an interface between the spar, the wing cover and the rib; wherein the assembly further comprises a seal member 7 which substantially covers the gap, and sealant provided between the seal member and the rib and/or the wing cover and/or the spar so as to seal the gap. Also a method for sealing a gap in an aircraft wing assembly.