Multi-ribbed Wing-box Co-curing with Support Inserts
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Solution Overview
Problem
Current methods for manufacturing aircraft wing-boxes, such as the 'build-up' configuration, are costly and heavy due to numerous parts and fastening members, and existing co-cured composite technologies are limited in applicability and unable to create wing-boxes with complex geometries or 'wet wing' configurations with communicating bays without structural defects.
Innovation Solution
A method involving a single curing process for a multi-ribbed wing-box with integrated stiffened panels and communicating bays, using support inserts and auxiliary tools to ensure stability and precision, allowing for the assembly of spars externally, and using pre-polymerized panels with a co-bonding process to avoid resin accumulation and weight increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the build-up configuration with multiple separate components is used, then the structural strength and stability are improved, but the production cost and weight increase significantly
Solution Approach 1:
The patent merges multiple separate structural components (panels, ribs, stringers) into a single integrated co-cured composite structure. This eliminates the need for numerous separate parts and mechanical fastening elements, directly resolving the contradiction between structural strength and device complexity by achieving both through monolithic construction.
Solution Approach 2:
The patent employs co-cured composite materials to create an integrated structure that combines the functions of multiple components. The composite material technology enables the manufacturing of complex geometries with high structural integrity while reducing the number of discrete parts, thereby addressing both strength requirements and complexity reduction.
2Stability of the object's composition
If the build-up configuration with mechanical fastening is used, then the structural stability is improved, but the weight and production cost increase
Solution Approach 1:
The patent combines multiple components into a single co-cured structure, eliminating mechanical fastening elements entirely. This merging approach maintains structural stability through the integrated monolithic construction while removing the weight of fasteners, holes, and associated reinforcement features.
Solution Approach 2:
The patent extracts and eliminates the mechanical fastening system from the structure. By removing rivets, bolts, and associated drilling operations, the design achieves structural stability through co-curing while eliminating the significant weight contribution from fastening members and localized thickening required to compensate for hole weakening.
3Weight of moving object
If the co-cured composite technology is used, then the weight and production cost are reduced, but the geometric flexibility and applicability are limited
Solution Approach 1:
The patent utilizes parameter changes in the co-curing process, including temperature, pressure, and resin composition, to achieve complex geometries that were previously impossible with traditional co-cured composite technology. This enables the method to accommodate highly curved aerodynamic profiles, inner thickening, and interrupted stringers while maintaining the weight advantages of co-curing.
Solution Approach 2:
The patent employs preliminary action by pre-positioning support inserts and auxiliary tools before the co-curing process to enable complex geometries. These preliminary arrangements allow the resin to properly fill and conform to intricate shapes during curing, thereby achieving geometric flexibility without sacrificing the weight benefits of co-cured construction.
4Adaptability or versatility
If openings are created for wet wing configuration, then the fuel communication between bays is enabled, but resin accumulation and structural defects occur
Solution Approach 1:
The patent applies preliminary action by pre-positioning support inserts in the desired opening locations before co-curing. These inserts maintain proper geometry and prevent resin accumulation during the curing process, enabling high-quality openings for wet wing configuration without structural defects.
Solution Approach 2:
The patent uses support inserts as intermediary elements during the co-curing process. These inserts mediate between the mold and the final structure, maintaining opening geometry and preventing resin accumulation. After curing, the inserts are removed to create clean, defect-free openings that enable fuel communication between bays.
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 method reduces production costs and weight, enhances structural stability, and allows for the creation of wing-boxes with complex geometries and 'wet wing' configurations, overcoming the limitations of existing technologies while maintaining structural integrity and reducing resin accumulation.
Implementation Method 1
a plurality of support inserts is arranged in openings of each rib and in contact with respective caul plates to ensure the stability of the openings during the curing process
Implementation Method 2
subjected jointly to a single curing process
Data Source
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AI summary
Method for manufacturing a wing-box (10) for aircraft by arranging a first composite panel (12a) comprising a skin (16) having a first side (16') and longitudinal stringers (18); arranging, on each stringer, a caul plate (23); arranging, on said first side, support inserts (20) along the transverse direction so that an intrados surface (20c) of the inserts rests on a respective caul plate, and a pair of feet (20d) of the support inserts rests on the skin; arranging, on said first side, non-polymerized composite ribs (14) in longitudinal direction , each comprising a plate (15), a first pair of flanges (15a) and a second pair of flanges (15b) at opposed ends of said plate, and having openings (14') on a edge (15c) of the plate, each rib in correspondence with aligned support inserts, by placing the respective first pair of flanges on said first side, and the respective plurality of openings on support inserts, so that each stringer extends through a respective opening of each rib; having the first panel and the ribs undergo a curing process.