阅读说明：本技术 具有格栅内部结构的后缘襟翼 (Trailing edge flap with grille interior ) 是由 S·P·沃克 P·G·马丁内兹 于 2020-10-22 设计创作，主要内容包括：本发明涉及具有格栅内部结构的后缘襟翼,一种飞机襟翼由飞机襟翼中的复合材料的嵌套层构造,该复合材料的嵌套层包括内层、中间层和外层。飞机襟翼被构造为内层围绕中心芯轴铺设,中间层围绕内层铺设,并且外层围绕中间层铺设。内层、中间层和外层在芯轴上共同固化,从芯轴上移除,并且然后与围绕飞机襟翼的中空内部体积以折叠配置形成的内层、在内层上以折叠配置形成的中间层以及以折叠配置围绕中间层形成的外层组装在一起。(The invention relates to a trailing edge flap with a grid inner structure, an aircraft flap is constructed from nested layers of composite material in an aircraft flap, the nested layers of composite material comprising an inner layer, an intermediate layer and an outer layer. The aircraft flap is configured such that the inner layer is laid around the central mandrel, the intermediate layer is laid around the inner layer, and the outer layer is laid around the intermediate layer. The inner, intermediate and outer layers are co-cured on a mandrel, removed from the mandrel, and then assembled with the inner layer formed in a folded configuration about a hollow interior volume of the aircraft flap, the intermediate layer formed in a folded configuration on the inner layer, and the outer layer formed in a folded configuration about the intermediate layer.)

1. An aircraft flap (12) comprising:

nested layers of composite material in an aircraft flap (12), the nested layers comprising an inner layer (14), an intermediate layer (16) and an outer layer (18);

the inner layer (14) having a folded configuration in the aircraft flap (12) integrally forming a lower panel (44), a middle panel (46) extending upwardly from the lower panel, and an upper panel (48) extending from the middle panel on the lower panel, the lower panel (44), the middle panel (46), and the upper panel (48) extending around a hollow interior volume (52) in the folded configuration of the inner layer (14);

the intermediate layer (16) having a folded configuration in the aircraft flap (12) integrally forming a lower panel (72) of the intermediate layer (16) overlying the lower panel (44) of the inner layer (14), a middle panel (74) of the intermediate layer (16) extending through the hollow interior volume (52) in the folded configuration of the inner layer (14), and an upper panel (76) of the intermediate layer (16) overlying the upper panel (48) of the inner layer (14); and is

The outer layer (18) has a folded configuration in the aircraft flap (12) to integrally form a lower panel (112) covering the outer layer (18) on the lower panel (72) of the intermediate layer (16), a middle panel (114) of the outer layer (18) extending over the middle panel (74) of the intermediate layer (16), and an upper panel (116) of the outer layer (18) covering the upper panel (76) of the intermediate layer (16).

2. The aircraft flap (12) of claim 1, further comprising:

the middle panel (46) of the inner layer (14) forms a first spar of the aircraft flap (12).

3. The aircraft flap (12) of claim 2, further comprising:

the middle panel (74) of the intermediate layer (16) forms a second spar of the aircraft flap (12).

4. The aircraft flap (12) of claim 3, further comprising:

the middle panel (114) of the outer layer (18) forms a rounded convex surface of the aircraft flap (12).

5. The aircraft flap (12) of any of claims 1-4, further comprising:

a plurality of holes (78) through the lower panel (72) of the intermediate layer (16); and

a plurality of holes (82) through the upper panel (76) of the intermediate layer (16).

6. The aircraft flap (12) of claim 5, further comprising:

each of the plurality of apertures (78, 82) has a polygonal configuration.

7. The aircraft flap (12) of any of claims 1-4, further comprising:

an internal support structure (118) in the hollow interior volume (52) in the folded configuration of the inner layer (14), the internal support structure (118) including a first rib (122) secured to the lower panel (44) and the upper panel (48) of the inner layer (14), a second rib (124) secured to the lower panel (44) and the upper panel (48) of the inner layer (14), and an intermediate spar (126) secured to the first rib (122) and the second rib (124).

8. A method of constructing an aircraft flap (12), the method comprising:

nesting layers of material in an aircraft flap (12), the layers of material including an inner layer (14), an intermediate layer (16), and an outer layer (18);

laying the inner layer (14) in a folded configuration about a central mandrel (32) to integrally form the inner layer (14), the inner layer having a lower panel (44), a middle panel (46) extending upwardly from the lower panel (44), and an upper panel (48) extending from the middle panel (46) on the lower panel (44), the middle panel (46), and the upper panel (48) extending about a hollow interior volume (52) in the folded configuration of the inner layer (14);

laying the intermediate layer (16) in a folded configuration around the inner layer (14) to integrally form the intermediate layer (16) having a lower panel (72) of the intermediate layer (16) overlying the lower panel (44) of the inner layer (14), a middle panel (74) of the intermediate layer (16) extending through the hollow interior volume (52) in the folded configuration of the inner layer (14), and an upper panel (76) of the intermediate layer (16) overlying the upper panel (46) of the inner layer (14); and

laying the outer layer (18) in a folded configuration around the intermediate layer (16) to integrally form the outer layer (18), the outer layer (18) having a lower panel (112) of the outer layer (18) overlying the lower panel (72) of the intermediate layer (16), a middle panel (114) of the outer layer (18) extending over the middle panel (74) of the intermediate layer (16), and an upper panel (116) of the outer layer (18) overlying the upper panel (76) of the intermediate layer (16).

9. The method of claim 8, further comprising:

forming a plurality of holes (78) through the lower panel (72) of the intermediate layer (16); and

forming a plurality of holes (82) through the upper panel (76) of the intermediate layer (16).

10. The method of claim 8 or 9, further comprising:

forming the middle panel (46) as the inner layer (14) of the first spar of the aircraft flap (12); and

forming the middle panel (74) as the intermediate layer (16) of a second spar of the aircraft flap (12).

Technical Field

The invention relates to the construction of trailing edge flaps of aircraft wings. In particular, the present invention relates to a composite structure for a trailing edge flap of an aircraft wing with minimal internal support structure and a simplified laminate design.

Background

Trailing edge flaps of aircraft wings can be used to increase the lift of the aircraft wing. The trailing edge flap is mounted to and selectively extends from or selectively retracts into a trailing edge of the aircraft wing.

Extending the trailing edge flap from the trailing edge of the aircraft wing increases the surface area of the underside of the aircraft wing. This in turn increases the lift of the aircraft wing. The increased lift of the aircraft wing enables the aircraft to generate the required lift at lower speeds (e.g., takeoff speed).

Existing trailing edge flaps are constructed using a number of parts and a number of fasteners. For example, existing trailing edge flaps may be constructed with thin aluminum skins extending across the upper and lower surfaces of the flap, with a number of internal stiffening elements between the skins. Constructing such a flap with an aluminum skin and a number of fasteners for fixing the skin to a number of internal stiffening elements is very time-consuming. The aluminum skin, many fasteners and many internal stiffening elements require a great deal of processing to manufacture the trailing edge flap. Furthermore, the aluminum skin of the existing trailing edge flaps, a number of fasteners and a number of internal stiffening elements also increase the weight of the trailing edge flaps.

Disclosure of Invention

The trailing edge flap and method of construction thereof of the present invention reduces the number of fasteners and stiffening elements in the trailing edge flap structure and reduces the manufacturing time of the trailing edge flap, thereby saving manufacturing time, reducing manufacturing costs, and reducing the weight of the trailing edge flap.

The trailing edge flap is constructed from nested layers of material comprising an inner layer, an intermediate layer and an outer layer. This material is a prepreg (pre-preg) composite material, but other types of materials may also be used.

The inner layer of material has a folded configuration in the aircraft flap that integrally forms the inner layer of material having a horizontally oriented lower panel, a vertically oriented middle panel extending upwardly from the lower panel, and an horizontally oriented upper panel extending from the middle panel above the lower panel. The lower, middle, and upper panels extend around the hollow interior volume in a folded configuration of the inner layer of material.

The intermediate layer of material has a folded configuration about the inner layer of material in the aircraft flap. The folded configuration of the intermediate layer of material forms an intermediate layer of material having: a lower panel of the middle layer of material oriented horizontally and overlying and placed on the lower panel of the inner layer of material, a middle panel of the middle layer of material oriented vertically and extending upwardly from the lower panel of the middle layer of material and through the hollow interior volume in the folded configuration of the inner layer of material, and an upper panel of the middle layer of material oriented horizontally and extending from the middle panel of the middle layer of material and overlying and placed on the upper panel of the inner layer of material.

The outer layer of material has a folded configuration about the intermediate layer of material and the inner layer of material in the aircraft flap. The folded configuration of the outer layer of material integrally forms the outer layer of material having: a lower panel of an outer layer of material oriented horizontally and overlying and resting on the lower panel of the intermediate layer of material, a middle panel of an outer layer of material oriented vertically and extending upwardly from the lower panel of the outer layer of material above the middle panel of the intermediate layer of material, and an upper panel of an outer layer of material oriented horizontally and extending from the middle panel of the outer layer of material and overlying and resting on the upper panel of the intermediate layer of material.

A central panel of an inner layer of material forms a first spar, for example a rear spar, inside the aircraft flap. The middle panel of the intermediate layer of material forms a second spar, such as a front spar, inside the aircraft flap. The central panel of the outer layer of material forms part of the exterior of the aircraft flap, for example the bow guide (bullnose) or a rounded convex surface of the aircraft flap.

A plurality of holes pass through the lower panel of the intermediate layer of material. There are also a plurality of apertures through the upper panel of the intermediate layer of material. These multiple holes remove the composite material from the structure of the intermediate layer of material and reduce the weight of the aircraft flap.

There is an internal support structure in the hollow interior volume in the folded configuration of the inner layer of material. The internal support structure includes a first rib in the hollow interior volume in a folded configuration of the inner layer of material. The first rib is secured to the inner layer of material. The internal support structure also includes a second rib in the hollow internal volume in the folded configuration of the inner layer of material. The second rib is secured to the inner layer of material. The internal support structure further includes an intermediate beam or an intermediate spar in the hollow internal volume in the folded configuration of the inner layer of material. The intermediate spar is located between the first spar and the second spar. The intermediate spar extends between and is secured to the first and second ribs.

A method of constructing an aircraft flap includes nesting a composite layer, an inner layer, an intermediate layer, and an outer layer in an aircraft flap. The composite layer is a prepreg composite layer. Other types of composite materials and other equivalent materials may be used.

The method of constructing includes laying an inner layer of material in a folded configuration about a central mandrel, the method integrally forming the inner layer of material having a lower panel, a middle panel extending upwardly from the lower panel, and an upper panel extending from the middle panel above the mandrel and the lower panel. The lower, middle, and upper panels of the inner layer of material extend around the central mandrel to form an inner layer of material extending around the hollow interior volume in the folded configuration of the inner layer of material.

The method of constructing further includes laying the intermediate layer of material in a folded configuration about the inner layer of material to integrally form the intermediate layer of material with the lower panel of the intermediate layer of material overlying and laying on the lower panel of the inner layer of material, the middle panel of the intermediate layer of material extending through the hollow interior volume in the folded configuration of the inner layer of material, and the upper panel of the intermediate layer of material overlying and laying on the upper panel of the inner layer of material.

The method of constructing still further includes laying an outer layer of material in a folded configuration about the intermediate layer of material to integrally form the outer layer of material, wherein a lower panel of the outer layer of material overlies and is laid upon the lower panel of the intermediate layer of material, a middle panel of the outer layer of material extends onto the middle panel of the intermediate layer of material, and an upper panel of the outer layer of material overlies and is laid upon the upper panel of the intermediate layer of material.

A plurality of apertures are formed through the lower panel of the intermediate layer of material and through the upper panel of the intermediate layer of material before the intermediate layer of material is laid around the inner layer of material in a folded configuration. The composite material removed from the lower panel of the intermediate layer of material and the upper panel of the intermediate layer of material reduces the weight of the aircraft flap.

Forming a central panel as an inner layer of material of a first spar (e.g., the rear spar of an aircraft flap) and forming a central panel as an intermediate layer of material of a second spar (e.g., the front spar of an aircraft flap) minimizes the internal support structure of the aircraft flap and simplifies the design of the laminate.

The features, functions, and advantages that have been discussed can be achieved independently in various examples or may be combined in yet other examples further details of which can be seen with reference to the following description and drawings.

Drawings

FIG. 1 is an illustration of a perspective view of a trailing edge flap of the invention.

FIG. 2 is an illustration of a perspective view of an inner layer of the trailing edge flap of FIG. 1.

FIG. 3 is an illustration of a perspective view of an intermediate layer of the trailing edge flap of FIG. 1.

FIG. 4 is an illustration of a perspective view of an outer layer of the trailing edge flap of FIG. 1.

FIG. 5 is an illustration of an end elevation view of an inner layer of a trailing edge flap formed on a central mandrel.

FIG. 6 is an illustration of an end elevation view of an intermediate layer of a trailing edge flap formed on a mandrel.

FIG. 7 is an illustration of an end elevation view of a front and rear mandrel attached to an intermediate layer of a trailing edge flap.

FIG. 8 is an illustration of an end elevation view of an outer layer of a trailing edge flap formed on a front mandrel, a central mandrel and a rear mandrel.

FIG. 9 is an illustration of an end elevation view of the inner, intermediate and outer layers of the trailing edge flap removed from the mandrel of FIGS. 7 and 8.

FIG. 10 is an illustration of a perspective view of the internal support structure of the trailing edge flap.

FIG. 11 is an illustration of an end elevation view of the internal support structure assembled to the inner layer.

Fig. 12 is an illustration of an end elevation view of a hole machined through an intermediate layer.

FIG. 13 is an illustration of the intermediate layer assembled to the inner layer and the internal support structure.

FIG. 14 is an illustration of an end elevation view of the outer layer assembled to the intermediate layer, the inner layer, and the internal support structure.

FIG. 15 is an illustration of a perspective view of a trailing edge flap with portions of the outer and intermediate layers removed to illustrate the configuration of the trailing edge flap.

Fig. 16 is an illustration of a perspective view of the aft rudder of the present invention.

FIG. 17 is an illustration of a perspective view of components of an aircraft aft rudder assembled with an internal support structure, an inner layer, an intermediate layer, and an outer layer.

Detailed Description

FIG. 1 is an illustration of a perspective view of a trailing edge flap 12 of the invention. The trailing edge flap 12 is constructed from nested layers of composite material, including an inner layer 14, an intermediate layer 16, and an outer layer 18. In the present invention, the composite material of each of the inner layer 14, the intermediate layer 16 and the outer layer 18 is a pre-impregnated composite material. However, other types of composite materials may be used to construct the layers to be described, and materials other than composite materials may be used.

FIG. 2 is an illustration of a perspective view of the inner layer 14 of material removed from the structure of the trailing edge flap 12 of FIG. 1. The inner layer of material 14 may be a single or monolithic composite material (e.g., a pre-impregnated composite material), or a multi-piece composite material. The inner layer of material 14 has a generally rectangular configuration with a longitudinal length extending between a medial edge 22 and an opposite lateral edge 24 of the inner layer of material 14 and a lateral width extending between a lower edge 26 and an opposite upper edge 28 of the inner layer of material 14. The longitudinal length of the inner layer of material 14 will extend along the longitudinal length of the trailing edge flap 12 to be constructed. The relative length and width dimensions of the inner layer 14 of material shown in fig. 2 are merely examples. The relative length and width dimensions of the inner layer 14 will vary depending on the length and width dimensions of the trailing edge flap being constructed. As shown in fig. 2, the inner layer of material 14 is formed into a folded configuration. By "folded configuration," it is meant that a portion of the inner layer 14 of material adjacent the upper edge 28 is overlapped or positioned on a portion of the inner layer 14 of material adjacent the lower edge 26. The folded configuration of the inner layer 14 of material shown in fig. 2 is achieved by folding the inner layer 14 of material over a central mandrel.

Fig. 5 is an illustration of an end elevation view of the inner layer 14 of material folded over the central mandrel 32. The central core shaft 32 has a bottom surface 34 and an opposing top surface 36, a first side surface 38 and an opposing second side surface 42. The length dimension of the central core shaft 32 depends on the length dimension of the configured trailing edge flap. As shown in fig. 5, the inner layer 14 of material is folded over the central mandrel 32 to form the folded configuration of the inner layer 14. The folded configuration of the inner layer 14 of material forms an inner layer having: a lower panel 44 on the bottom surface 34 of the central mandrel 32, a middle panel 46 on the first side surface 38 of the central mandrel, and an upper panel 48 on the top surface 36 of the central mandrel 32. Folding the inner layer of material 14 over the central mandrel 32 integrally forms the inner layer of material 14 having: a horizontally oriented lower panel 44, a vertically oriented middle panel 46 extending upwardly from the lower panel 44, and an upper panel 48 horizontally oriented and extending from the middle panel 46 to above the lower panel 44. The lower, middle, and upper panels 44, 46, 48 of the inner layer of material 14 extend around a hollow interior volume 52 in the folded configuration of the inner layer of material 14.

FIG. 3 is an illustration of a perspective view of the intermediate layer 16 of material removed from the structure of the trailing edge flap 12 of FIG. 1. As with the inner layer of material 14, the intermediate layer of material 16 may be a single layer or sheet of composite material (e.g., a pre-impregnated composite material), or a multi-sheet composite material. The illustration of the central layer of material 16 in fig. 3 has a generally rectangular configuration with a longitudinal length extending between a medial edge 62 and an opposite lateral edge 64 of the central layer of material 16 and a lateral width extending between a lower edge 66 and an opposite upper edge 68 of the inner layer of material 16. The rectangular configuration of the intermediate layer 16 of material is only one example of a possible configuration. The configuration of the intermediate layer of material 16 will vary based on the configuration of the trailing edge flap being constructed. As with the inner layer 14 of material, the longitudinal length of the intermediate layer 16 of material will extend along the longitudinal length of the trailing edge flap 12 to be constructed. The relative length and width dimensions of the intermediate layer 16 of material shown in fig. 3 are merely exemplary. The relative length and width dimensions of the intermediate layer of material 16 will vary based on the length and width dimensions of the trailing edge flap being constructed. As shown in fig. 3, the intermediate layer of material 16 is formed in a folded configuration. By "folded configuration" it is meant that a portion of the intermediate layer 16 of material adjacent the upper edge 68 is overlapped or positioned on a portion of the intermediate layer 16 of material adjacent the lower edge 66. The folded configuration of the intermediate layer of material 16 shown in fig. 3 is achieved by folding the intermediate layer of material 16 onto the inner layer of material 14 on the central mandrel 32.

Fig. 6 is an illustration of an end elevational view of the intermediate layer of material 16 folded over the inner layer of material 14, the inner layer of material 14 having previously been folded over the central mandrel 32. A release agent is applied to the lower panel 44 of the inner layer, the middle panel 46 of the inner layer and the upper panel 48 of the inner layer before the middle layer 16 is folded over the inner layer 14. The intermediate layer 16 is then folded over the inner layer 14 to form the folded configuration of the intermediate layer 16. The folded configuration of the intermediate layer of material 16 forms an intermediate layer having a lower panel 72 overlying and laying on the lower panel 44 of the inner layer 14, a middle panel 74 overlying and laying on the second side surface 42 of the central mandrel 32, and an upper panel 76 overlying and laying on the upper panel 48 of the inner layer 14. The intermediate layer 16 of material is formed on the inner layer 14 of material previously folded over the central mandrel 32, which integrally forms the intermediate layer 16 of material with the lower panel 72 of the intermediate layer being horizontally oriented, the middle panel 74 of the intermediate layer being vertically oriented and extending upwardly from the lower panel 72 of the intermediate layer, and the upper panel 76 being horizontally oriented and extending from the middle panel 74 onto the lower panel 72 of the intermediate layer and the upper panel 48 of the inner layer 14. The lower 72, middle 74, and upper 76 panels of the middle layer of material 16 extend around the inner layer of material 14 and the hollow interior volume 52 in the folded configuration of the inner layer of material 14.

As shown in fig. 3, a plurality of holes 78 are formed through the lower panel 72 of the middle layer 16. Each of the plurality of apertures 78 has a polygonal configuration. A plurality of apertures 82 are also formed through the upper face sheet 76 of the intermediate layer 16. Each of these plurality of apertures 82 also has a polygonal configuration. The plurality of holes 78, 82 are formed in the intermediate layer of material 16 during a post-fabrication step of the intermediate layer of material. The plurality of holes 78, 82 remove the composite material from the structure of the intermediate layer of material 16, thereby reducing the weight of the intermediate layer of material 16 and the weight of the trailing edge flap 12 constructed from the intermediate layer of material 16.

FIG. 4 is an illustration of a perspective view of an outer layer 18 of material removed from the structure of the trailing edge flap 12 of FIG. 1. Like the inner layer of material 14 and the intermediate layer of material 16, the outer layer of material 18 may be a single layer or sheet of composite material (e.g., a pre-impregnated composite material), or a multi-layer composite material. As shown in FIG. 4, the outer layer of material 18 has a generally rectangular configuration with a longitudinal length extending between a medial edge 84 and an opposite lateral edge 86 of the outer layer of material 18 and a lateral width extending between a lower edge 88 and an opposite upper edge 92 of the outer layer of material 18. The longitudinal length of the outer layer of material 18 will extend along the longitudinal length of the trailing edge flap being constructed. The relative length and width dimensions of the outer layer 18 of material shown in fig. 4 are merely exemplary. The relative length and width dimensions of the outer layer of material 18 will vary depending on the length and width dimensions of the trailing edge flap being constructed. As shown in fig. 4, the outer layer 18 of material is formed in a folded configuration. By "folded configuration," it is meant that a portion of the outer layer 18 of material adjacent the upper edge 92 is overlapped or positioned on a portion of the outer layer 18 of material adjacent the lower edge 88. The folded configuration of the outer layer 18 of material shown in fig. 4 is achieved by folding the outer layer 18 of material over the intermediate layer 16 of material, over the inner layer 14 of material, and over the central mandrel 32.

The inner layer of material 14 and the central mandrel 32, the front mandrel 94 and the rear mandrel 96 are added to the central mandrel 32 before the outer layer of material 18 is folded over the intermediate layer of material 16 in its folded configuration.

As shown in fig. 7, the front spindle 94 has a flat rear surface 98 that is positioned against the middle panel 74 of the middle tier. The front spindle 94 also has a front surface 102 that projects outwardly from the flat rear surface 98. The front surface 102 has a generally semi-circular configuration in cross-section. The length dimension of the front mandrel 94 depends on the length dimension of the configured trailing edge flap.

The rear mandrel 96 has a front surface 104 that is positioned against the middle panel 74 of the middle layer 16. The rear spindle 96 has a rear surface 106 projecting rearwardly from the front surface 104. The rear surface 106 provides the rear spindle 96 with a triangular cross-sectional configuration. The length dimension of the rear spindle 96 depends on the length dimension of the configured trailing edge flap.

Fig. 8 is an illustration of an end elevation view of the outer layer 18 of material folded over the front mandrel 94, the intermediate layer 16 folded over the inner layer 14 of material and the central mandrel 32, and the rear mandrel 96. A release agent, such as a release film, is applied to the front mandrel front surface 102, the intermediate layer lower panel 72, the intermediate layer upper panel 76 and the rear mandrel rear surface 106 before folding the outer layer 18 of material over the front mandrel 94, the intermediate layer 16 of material and the rear mandrel 96. As shown in fig. 8, the outer layer 18 of material is folded over the front mandrel 94, the lower panel 72 of the intermediate layer, the upper panel 76 of the intermediate layer, and the rear mandrel 96 to form a folded configuration of the outer layer 18 of material. The folded configuration of the outer layer 18 forms an outer layer having: a lower panel 112 overlying and laying on the lower panel 72 of the middle layer 16 and the rear surface 106 of the rear spindle 96, a middle panel 114 lying on the front surface 102 of the front spindle 94, and an upper panel 116 overlying and laying on the upper panel 76 of the middle layer 16 of material and the rear surface 106 of the rear spindle 96. Folding outer layer 18 of material over front mandrel 94, intermediate layer 16 of material, and rear mandrel 96 integrally forms outer layer 18 of material having a horizontally oriented lower panel 112, a vertically oriented middle panel 114 extending upwardly from lower panel 112, and a horizontally oriented upper panel 116 extending from middle panel 114 to above lower panel 112. The lower 112, middle 114, and upper 116 panels of the outer layer of material 18 extend around the hollow interior volume 52 in the folded configuration of the inner layer of material 14. The inner layer of material 14, the intermediate layer of material 16, and the outer layer of material 18 assembled on the central mandrel 32, the front mandrel 94, and the rear mandrel 96 as shown in fig. 8 are then autoclaved. The autoclave process causes the inner layer of material 14, the intermediate layer of material 16, and the outer layer of material 18 to be heated and pressurized to cure the inner layer of material 14, the intermediate layer of material 16, and the outer layer of material 18. After autoclave processing, the inner layer of material 14, the intermediate layer of material 16, and the outer layer of material 18 are removed from the central mandrel 32, the front mandrel 94, and the rear mandrel 96. Fig. 9 is an illustration of an end elevation view of the inner layer of material 14, the intermediate layer of material 16, and the outer layer of material 18 after removal from the mandrel.

FIG. 10 is an illustration of a perspective view of the internal support structure 118 of the trailing edge flap 12. The inner support structure 118 includes a first rib 122. The first rib 122 is constructed of metal or other equivalent material. The first ribs 122 have an outer surface configuration or an outer peripheral surface configuration that conforms to the inner surface of the inner layer 14 of material shown in fig. 9. The inner support structure 118 also includes a second rib 124. The second ribs 124 have substantially the same outer configuration or outer peripheral surface configuration as the first ribs 122. The second ribs 124 are also constructed of metal or other equivalent material. The configuration of the outer surface of the second ribs 124 also follows the configuration of the inner surface of the inner layer 14 of material as shown in fig. 9. The internal support structure 118 further includes an intermediate beam or spar 126. The intermediate spar 126 is made of composite material or other equivalent material. As shown in fig. 10, the intermediate spar 126 extends between the first rib 122 and the second rib 124 and is secured to the first rib 122 and the second rib 124.

In constructing the trailing edge flap 12, the internal support structure 118 is positioned in the hollow interior volume 52 of the inner layer 14 of material. Fig. 11 is an illustration of an end elevation view of the internal support structure 118 inserted into the hollow interior volume 52 of the inner layer 14 of material. The first rib 122 is secured to the inner layer of material 14 by fasteners or other equivalent means. The second rib 124 is secured to the inner layer of material 14 by fasteners or other equivalent means.

A plurality of holes 78 are then formed through the lower panel 72 of the intermediate layer 16 of material. A plurality of apertures 82, shown in fig. 3, are also formed through the upper panel 76 of the intermediate layer 16 of material. As shown in fig. 3, the plurality of apertures 78, 82 have a polygonal configuration. This positions the edges of the plurality of holes 78, 82 parallel to the fibers of the composite material of the intermediate layer of material 16. The plurality of holes 78, 82 remove the composite material from the structure of the intermediate layer of material 16 and reduce the weight of the intermediate layer of material 16 and the weight of the trailing edge flap 12. Fig. 12 is an illustration of a front cross-sectional view through the middle layer of material 16 with a plurality of holes 78 through the lower panel 72 of the middle layer of material 16 and a plurality of holes 82 through the upper panel 76 of the middle layer of material 16.

Fig. 13 is an illustration of an end elevational view of the intermediate layer of material 16 assembled onto the inner layer of material 14 that has previously been secured to the internal support structure 118 located within the hollow interior volume 52 of the inner layer of material 14. As shown in fig. 13, the intermediate layer of material 16 is assembled to the inner layer of material 14 with a thin film adhesive layer between the multiple interfaces of the intermediate layer of material 16 and the inner layer of material 14. The inner layer of material 14, the intermediate layer of material 16 and the outer layer of material 18 shown in figure 9 are resilient after autoclave treatment. This enables the inner layer of material 14, the intermediate layer of material 16 and the outer layer of material 18 to be assembled to one another.

With the intermediate layer of material 16 assembled on the inner layer of material 14 in its folded configuration, the outer layer of material 18 is assembled on the intermediate layer of material 16 in its folded configuration. Prior to assembly of the outer layer of material 18 to the intermediate layer of material 16, a thin film of adhesive is applied between the various interfaces of the outer layer of material 18 and the intermediate layer of material 16. Fig. 14 is an end view of an outer layer 18 of material assembled over an intermediate layer 16 of material. With the outer layer of material 18 assembled on the intermediate layer of material 16 as shown in fig. 14, the cleat 132 of the composite material is positioned between the lower panel 112 of the outer layer of material 18 and the upper panel 116 of the outer layer of material 18 at the lower edge 88 of the outer layer of material 18 and the upper edge 92 of the outer layer of material 18. The key 132 is positioned as shown in fig. 14.

The assembled internal support structure 118, inner layer of material 14, intermediate layer of material 16, outer layer of material 18 and key 132 shown in fig. 14 are then vacuum packed and hot pressed again. This forms a secondary cure bond between the inner layer of material 14, the intermediate layer of material 16, the outer layer of material 18, and the key 132. After the second autoclave treatment, the construction of the trailing edge flap 12 is completed. FIG. 15 is an illustration of a perspective view of trailing edge flap 12 with portions of outer layer 18 and intermediate layer 16 removed to illustrate the structure of trailing edge flap 12. In the construction of the finished trailing edge flap 12, the middle panel 46 of the inner layer 14 of material forms a first or rear spar in the trailing edge flap 12, the middle panel 74 of the middle layer 16 of material forms a second or front spar in the trailing edge flap 12, and the middle panel 114 of the outer layer 18 of material forms a bullnose of the trailing edge flap 12.

Although the present invention describes the construction of the trailing edge flap 12, the inventive concept can also be used to manufacture other structures of an aircraft. For example, the concepts of the present invention may be used to manufacture vertical tail and rudder assemblies for aircraft. Fig. 16 is a schematic view of components that would enter the configuration of the aft rudder 134. Fig. 16 is a schematic illustration of an inner layer 136 of material, an intermediate layer 138 of material, and an outer layer 142 of material, each formed of composite material (e.g., pre-impregnated composite material). The aft rudder 134 also has an internal support structure in the form of a plurality of ribs 144. The ribs 144 are made of metal or other equivalent material. The inner layer of material 136, the intermediate layer of material 138, the outer layer of material 142 and the ribs 144 are assembled together in the same manner as the construction of the trailing edge flap 12 to form the aft rudder 134.

Furthermore, the invention includes embodiments according to the following clauses:

clause 1. an aircraft flap 12, comprising:

nested layers of composite material in aircraft flap 12, including inner layer 14, intermediate layer 16, and outer layer 18;

the inner layer 14 has a folded configuration in the aircraft flap 12, integrally forming a lower panel 44, a middle panel 46 extending upwardly from the lower panel, and an upper panel 48 extending from the middle panel above the lower panel, the lower panel 44, middle panel 46, and upper panel 48 extending around a hollow interior volume 52 in the folded configuration of the inner layer 14;

the intermediate layer 16 has a folded configuration in the aircraft flap 12 to integrally form a lower panel 72 of the intermediate layer 16 overlying the lower panel 44 of the inner layer 14, a middle panel 74 of the intermediate layer 16 extending through the hollow interior volume 52 in the folded configuration of the inner layer 14, and an upper panel 76 of the intermediate layer 16 overlying the upper panel 48 of the inner layer 14, and

outer layer 18 has a folded configuration in aircraft flap 12 to integrally form a lower panel 112 of outer layer 18 overlying lower panel 72 of intermediate layer 16, a middle panel 114 of outer layer 18 extending over middle panel 74 of intermediate layer 16, and an upper panel 116 of outer layer 18 overlying upper panel 76 of intermediate layer 16.

Clause 2. the aircraft flap 12 of clause 1, further comprising:

the middle panel 46 of the inner layer 14 forms a first spar of the aircraft flap 12.

Clause 3. the aircraft flap 12 according to clause 2, further comprising:

the middle panel 74 of the intermediate layer 16 forms a second spar of the aircraft flap 12.

Clause 4. the aircraft flap 12 according to clause 3, further comprising:

the middle panel 114 of the outer layer 18 forms a rounded convex surface of the aircraft flap 12.

Clause 5. the aircraft flap 12 according to any one of clauses 1-5, further comprising:

a plurality of holes 78 through the lower panel 72 of the middle layer 16; and

a plurality of holes 82 through the upper panel 76 of the middle layer 16.

Clause 6. the aircraft flap 12 according to clause 5, further comprising:

each of the plurality of apertures 78, 82 has a polygonal configuration.

Clause 7. the aircraft flap 12 according to any one of clauses 1-6, further comprising:

an internal support structure 118 located in the hollow interior volume 52 in the folded configuration of the inner layer 14, the internal support structure 118 including a first rib 122 secured to the lower and upper panels 44, 48 of the inner layer 14, a second rib 124 secured to the lower and upper panels 44, 48 of the inner layer 14, and an intermediate spar 126 secured to the first and second ribs 122, 124.

Clause 8. an aircraft flap 12, comprising:

an inner layer 14 of material having a folded configuration, the folded configuration forming the inner layer 14 of material having: a horizontally oriented lower panel 44, a vertically oriented middle panel 46 extending upwardly from the lower panel 44, and an upper panel 48 horizontally oriented and extending from the middle panel 46 on the lower panel 44, the lower, middle, and upper panels 44, 46, 48 extending around a hollow interior volume 52 in the folded configuration of the inner layer 14 of material;

an intermediate layer of material 16 having a folded configuration about the inner layer of material 14, the folded configuration forming the intermediate layer of material 16 having: a lower panel 72 of the middle layer 16 of material oriented horizontally and laid over the lower panel 44 of the inner layer 14 of material, a middle panel 74 of the middle layer 16 of material oriented vertically and extending upwardly from the lower panel 72 of the middle layer 16 of material and through the hollow interior volume 52 in the folded configuration of the inner layer 14 of material, and an upper panel 76 of the middle layer 16 of material oriented horizontally and extending from the middle panel 74 of the middle layer 16 of material and laid over the upper panel 48 of the inner layer 14 of material; and

an outer layer 18 of material having a folded configuration about the intermediate layer 16 of material and the inner layer 14 of material, the folded configuration of the outer layer 18 of material forming the outer layer 18 of material having: a lower panel 112 oriented horizontally and laid over the lower panel 72 of the intermediate layer of material 16, a middle panel 114 of the outer layer of material 18 oriented vertically and extending upwardly from the lower panel 112 of the outer layer of material 18 to above the middle panel 74 of the intermediate layer of material 16, and an upper panel 116 of the outer layer of material 18 oriented horizontally and extending from the middle panel 114 of the outer layer of material 18 and laid over the upper panel 76 of the intermediate layer of material 16.

Clause 9. the aircraft flap 12 according to clause 8, further comprising:

the middle panel 46 of the inner layer 14 of material forms a first spar of the aircraft flap.

Clause 10. the aircraft flap 12 according to clause 9, further comprising:

the middle panel 74 of the intermediate layer 16 of material forms a second spar of the aircraft flap.

Clause 11. the aircraft flap 12 of clause 10, further comprising:

the middle panel 114 of the outer layer 18 of material forms a rounded convex surface of the aircraft flap 12.

Clause 12. the aircraft flap 12 according to any one of clauses 8-11, further comprising:

the lower panel 44 of the inner layer of material 14, the middle panel 46 of the inner layer of material 14, and the upper panel 48 of the inner layer of material 14 are integrally formed.

Clause 13. the aircraft flap 12 of clause 12, further comprising:

the lower panel 72 of the intermediate layer of material 16, the middle panel 74 of the intermediate layer of material 16, and the upper panel 76 of the intermediate layer of material 16 are integrally formed.

Clause 14. the aircraft flap 12 of clause 13, further comprising:

the lower panel 112 of the outer layer of material 18, the middle panel 114 of the outer layer of material 18, and the upper panel 116 of the outer layer of material 18 are integrally formed.

Clause 15. the aircraft flap 12 of any of clauses 8-14, further comprising:

the inner layer 14 of material is a composite material;

the intermediate layer of material 16 is a composite material; and

the outer layer 18 of material is a composite material.

Clause 16. the aircraft flap 12 according to any one of clauses 8-15, further comprising:

a plurality of holes 78 through the lower panel 72 of the intermediate layer 16 of material; and

a plurality of holes 82 through the upper panel 76 of the intermediate layer 16 of material.

Clause 17. the aircraft flap 12 according to any one of clauses 8-16, further comprising:

a first rib 122 in the hollow interior volume 52 in the folded configuration of the inner layer 14 of material, the first rib 122 secured to the inner layer 14 of material;

a second rib 124 in the empty interior volume 52 in the folded configuration of the inner layer 14 of material, the second rib 122 being secured to the inner layer 14 of material; and

an intermediate spar 126 in the empty interior volume 52 in the folded configuration of the inner layer 14 of material, the intermediate spar 126 being secured to the first rib 122 and the second rib 124.

Clause 18. a method of constructing an aircraft flap 12, the method comprising:

nesting layers of material in an aircraft flap 12, the layers of material including an inner layer 14, an intermediate layer 16, and an outer layer 18;

laying the inner layer 14 in a folded configuration about the central mandrel 32 to integrally form the inner layer 14 having: a lower panel 44, a middle panel 46 extending upwardly from the lower panel 44, and an upper panel 48 extending from the middle panel 46 above the lower panel 44, the lower, middle, and upper panels 44, 46, 48 extending around a hollow interior volume 52 in the folded configuration of the inner layer 14;

laying the intermediate layer 16 in a folded configuration around the inner layer 14, thereby integrally forming the intermediate layer 16 having: a lower panel 72 of the middle layer 16 overlying the lower panel 44 of the inner layer 14, a middle panel 74 of the middle layer 16 extending through the hollow interior volume 52 in the folded configuration of the inner layer 14, and an upper panel 76 of the middle layer 16 overlying the upper panel 46 of the inner layer 14; and

laying an outer layer 18 in a folded configuration about the intermediate layer 16, thereby integrally forming the outer layer 18 having: a lower panel 112 of the outer layer 18 overlying the lower panel 72 of the middle layer 16, a middle panel 114 of the outer layer 18 extending to the middle panel 74 of the middle layer 16, and an upper panel 116 of the outer layer 18 overlying the upper panel 76 of the middle layer 16.

Clause 19. the method of clause 18, further comprising:

forming a plurality of holes 78 through the lower panel 72 of the intermediate layer 16, an

A plurality of holes 82 are formed through the upper panel 76 of the middle layer 16.

Clause 20. the method of any of clauses 18-19, further comprising:

a middle panel 46 forming the inner layer 14 as a first spar of the aircraft flap 12, and

a middle panel 74 is formed as an intermediate layer 16 of the second spar of the aircraft flap 12.

As various modifications could be made in the construction of the trailing edge flaps and methods of construction thereof described and illustrated herein without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Thus, the breadth and scope of the present invention should not be limited by any of the above-described examples, but should be defined only in accordance with the following claims appended hereto and their equivalents.