Wing flap with torque member and method of forming the same

Abstract

A wing flap and a method for forming the same. The wing flap (100) includes a flap body (164) and a torque member (210). The torque member is integrally formed with at least a portion of the flap body (164).

Description

Technical Field

[0001] The present invention relates generally to aircraft and, more particularly, to an aircraft wing flap having a torque member integrally formed with at least a portion of a flap body and a method of forming the wing flap. Background Art

[0002] Fixed-wing aircraft typically include various flight control surfaces that can adjust and control the flight of the aircraft. For example, flaps mounted on the trailing edge of the wing change the effective profile of the wing, thereby changing the lift characteristics of the wing. In some types of flap systems, the inboard flap includes a torque member for moving the flap between a stowed position and a deployed position. Typically, the torque member extends into the side of the fuselage, or into the wing fairing structure of the fuselage, and is coupled to a flap support mechanism that controls the movement of the flap.

[0003] In many flap systems, the torque member is a tubular structure with a circular cross-sectional shape, commonly referred to as a torque tube. The torque tube is typically coupled to a structural member of the flap, such as an inboard rib. However, to obtain appropriate structural and load bearing performance, a heavy torque tube and large, complex couplings may be required, which increases the weight and cost of the aircraft. In addition, some flap systems utilize a fail-safe torque tube that includes a dual torque tube design, which further increases the cost, weight, and complexity of the aircraft.

[0004] Accordingly, those skilled in the art continue to conduct research and development in the field of aircraft wing flap actuation. Summary of the invention

[0005] In one example, a wing flap is disclosed that includes a flap body and a torque member integrally formed with at least a portion of the flap body.

[0006] In one example, an aircraft wing is disclosed that includes a wing body and a wing flap. The wing flap includes a flap body movably coupled to the wing body and includes a torque member integrally formed with at least a portion of the flap body.

[0007] In one example, the disclosed method includes the step of integrally forming a torque member with at least a portion of a flap body to form a wing flap. The flap body is configured to be movably coupled to a wing of an aircraft. The torque member is configured to be coupled to a flap actuator of the aircraft.

[0008] Other examples of the disclosed wing flap and method will become apparent from the following detailed description, accompanying drawings, and appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a schematic perspective view of an example of an aircraft;

[0010] Figure 2 is a schematic perspective view of an example of an aircraft wing;

[0011] Figure 3 is a schematic perspective view of an example of the disclosed wing flap;

[0012] Figure 4 is a schematic interior perspective view of an example of a portion of an aircraft showing an example of a torque member of a disclosed wing flap extending through an opening in an aircraft fuselage;

[0013] Figure 5 is a schematic partial perspective view of an example of the disclosed wing flap;

[0014] Figure 6 is a schematic front view and a cross-sectional view of an example of a disclosed wing flap;

[0015] Figure 7 is a schematic partial plan view of an example of the disclosed wing flap;

[0016] Figure 8 is a schematic plan view of an example of the disclosed wing flap;

[0017] Fig. 9 is a schematic partial plan view of an example of the disclosed wing flap;

[0018] Fig.10 is a schematic partial plan view of an example of the disclosed wing flap;

[0019] Fig.11 is a schematic partial plan view of an example of the disclosed wing flap;

[0020] Fig.12 is a schematic partial plan view of an example of the disclosed wing flap;

[0021] Fig.13 is a schematic partial plan view of an example of the disclosed wing flap;

[0022] Fig.14 is a schematic partial plan view of an example of the disclosed wing flap;

[0023] Fig.15 is a schematic partial plan view of an example of the disclosed wing flap;

[0024] Fig.16 is a schematic partial plan view of an example of the disclosed wing flap;

[0025] Fig.17 is a schematic partial plan view of an example of the disclosed wing flap;

[0026] Fig.18 is a schematic partial plan view of an example of the disclosed wing flap;

[0027] Fig.19 is a schematic perspective view of an example of the disclosed wing flap;

[0028] Fig. 20 is a flowchart of an example of the disclosed method; and

[0029] Fig.21 is a flow chart of an exemplary aircraft production and service methodology. DETAILED DESCRIPTION

[0030] The following detailed description refers to the accompanying drawings, which show specific examples described in the present disclosure. Other examples with different structures and operations do not depart from the scope of the present disclosure. In different drawings, the same reference numerals may refer to the same features, elements or components.

[0031] The following provides illustrative, non-exhaustive examples of subject matter in accordance with the present disclosure, which may be, but are not necessarily, claimed.

[0032] Figure 1 2 is an illustrative example of aircraft 200. In the illustrative example, aircraft 200 is a fixed-wing aircraft. Aircraft 200 includes fuselage 202, a pair of wings 214 (also individually referred to as wings 214), and propulsion system 216. Aircraft 200 also includes a number of high-level systems, such as, but not limited to, electrical system 226, hydraulic system 228, and / or environmental system 230. Any number of other systems may also be included.

[0033] Fuselage 202 is the main body of aircraft 200 and includes any suitable central structure configured to accommodate a crew, one or more passengers, and / or cargo. In the illustrative example, fuselage 202 is an elongated, generally cylindrical fuselage. Fuselage 202 includes a front portion at the front end of fuselage 202 and a tail portion at the rear end of fuselage 202. As used herein, the terms "forward" and "rearward" have ordinary meanings known to those skilled in the art and refer to positions relative to the direction of movement of aircraft 200. The tail portion may also include a vertical stabilizer 240 and a horizontal stabilizer 238.

[0034] The fuselage 202 includes a frame 222 defining an interior 224, which may include a passenger cabin and / or a cargo hold. A wing fairing structure 220 (e.g., a fuselage / wing fairing) may also be disposed at each junction between the fuselage 202 and the wing 214 and may extend from adjacent to the fuselage 202 (at or near the fuselage) to adjacent to the wing 214 with which it is associated.

[0035] Wing 214 includes any suitable airfoil structure configured to provide lift to aircraft 200. In the illustrative example, wing 214 is an elongated structure extending from a lower portion of fuselage 202 in a swept-wing, tapered configuration. In other examples, wing 214 is straight or triangular. In still other examples, wing 214 is trapezoidal, constant, elliptical, semi-elliptical, or other configurations known in the art.

[0036] In the illustrative example, propulsion system 216 includes two turbofan engines, which are mounted on wing 214, for example, via pylons. In one example, each engine is housed in an engine nacelle, which includes an inlet and a nozzle. In other examples, the engine can be mounted to fuselage 202 or other aircraft structures, such as a tail section. In various other examples, propulsion system 216 can include more or fewer engines, and other types of engines (e.g., turboprop engines) can be used.

[0037] Aircraft 200 includes various flight control surfaces 232. Flight control surfaces 232 include any pivoting aerodynamic devices for adjusting and controlling the flight and aerodynamic characteristics of aircraft 200. Examples of flight control surfaces 232 include inboard flaps 208 and / or outboard flaps 218 at the tail end of wing 214, elevators 234 at the tail end of horizontal stabilizers 238, rudders 236 at the tail end of vertical stabilizers 240, and other control surfaces, such as nose flaps, ailerons, and spoilers. As used herein, the terms "inboard" and "outboard" have common meanings known to those skilled in the art and refer to locations relative to the centerline of aircraft 200.

[0038] In one example, inboard flap 208 (also referred to as each inboard flap 208) and / or outboard flap 218 (also referred to as each outboard flap 218) comprise and be installed on wing 214 trailing edge and be configured to pivot, rotate and / or translate (for example, forward and backward) any suitable structure with respect to wing 214.Inboard flap 208 and / or outboard flap 218 are all configured to change the lift characteristics of wing 214.Inboard flap 208 and / or outboard flap 218 can move between at least raising (storing, retracting or " flaps are put up ") position and lowering (unfolding, extending or " flaps are put down ") position.In one example, inboard flap 208 and / or outboard flap 218 can pivot around fixed axis.In one example, inboard flap 208 and / or outboard flap 218 all pivot through predetermined path, and this predetermined path is arcuate normally.

[0039] In one example, aircraft 200 also includes flap actuators 260. Flap actuators 260 are associated with each wing 214 for actuating inboard flaps 208. In one example, flap actuators 260 include motorized arms located or housed within fuselage 202 or wing fairing structure 220.

[0040] In one example, the torque member 210 couples the flap actuator 260 with the associated inboard flap 208 to transfer the actuation / deactuation (e.g., lowering / raising) force from the flap actuator 260 to the associated inboard flap 208. The torque member 210 extends through an opening 206 in the aircraft 200 (e.g., an opening 206 in the fuselage 202 or a wing fairing structure 220). The size and shape of the opening 206 in the aircraft 200 are designed to accommodate the travel path of the torque member 210 when the inboard flap 208 is lowered and raised.

[0041] Figure 2 It is an illustrative example of wing 214. Wing 214 is any one of various wing structures including wing body 258. Wing body 258 is formed by various structural members, including but not limited to upper wing skin 246, lower wing skin 248, multiple spars 250 extending between upper wing skin 246 and lower wing skin 248, and multiple ribs 252 extending between upper wing skin 246 and lower wing skin 248. These structural members are connected together by any of various methods, including but not limited to being connected, co-cured or integrally formed by various fasteners. Spars 250 extend between wing root 254 of wing 214 and wing end 256 of wing 214 along the span direction. Ribs 252 extend between leading edge 244 of wing 214 and trailing edge 242 of wing 214 along the chord direction. Wing 214 also includes wing flap 100. The disclosed example of the wing flap 100 may be movably coupled to the wing 214 at the trailing edge 242 of the wing 214 adjacent to the wing root 254 .

[0042] refer to Figures 3 to 19 , various examples of wing flaps 100 are disclosed. The disclosed wing flap 100 includes a flap body 164 and a torque member 108 integrally formed with at least a portion of the flap body 164. The torque member 108 extends from the inboard end 124 of the flap body 164 in the inboard direction. As used herein, the phrase "integrally formed" refers to a part (e.g., component or part) that is part of, belongs to, or is related to an integral whole, wherein the parts are organically joined or connected during the forming process to form an integral whole, and more than just interconnected parts are required.

[0043] In one example, the torque member 108 is coupled to at least one structural member 198 ( Figure 6 and Figure 7 ) is integrally formed. As used herein, the phrase "structural member" refers to any one of a plurality of structural members 198 that partially form the wing flap 100, and refers to a load-bearing element that is configured to carry a load or react to a stress applied to the wing flap 100. Typically, the structural members 198 that partially form the wing flap 100 include, but are not limited to, spars, ribs, stringers, etc. For example, the flap body 164 and the torque member 108 share a common structural member 198, such as a spar 106 extending along the wing flap 100 in the spanwise direction. In one example, the flap body 164 includes an outer skin (e.g., an upper skin 102 and a lower skin 104) and a plurality of spars 106, and the torque member 108 is integrally formed by a portion of at least one spar extending from the flap body 164 in the inner direction in a plurality of spars 106. Therefore, as discussed in more detail below, the wing flap 100 includes an upper skin 102 and a lower skin 104. The wing flap 100 also includes a plurality of spars 106 extending between the upper skin 102 and the lower skin 104 .

[0044] By utilizing a portion of the existing structure of the flap body 164 to form at least a portion of the torque member 108, the torque member 108 integrally formed with at least a portion of the flap body 164 can reduce the cost, complexity, and / or weight of the wing flap 100. As an example, the torque member 108 integrally formed with at least a portion of the flap body 164 can reduce the complexity and cost that is typically associated with the connection between a torque member (e.g., a conventional torque tube) and an inboard flap of an aircraft wing. For example, forming the torque member 108 from a portion of an existing structural member 198 (e.g., a spar 106) of the wing flap 100 is less expensive than manufacturing a metal (e.g., titanium or steel) torque tube, reduces the parts and time required to assemble and join a metal torque tube to a wing flap, and reduces concentrated load locations formed at the joint.

[0045] As another example, a torque member 108 integrally formed with at least a portion of the flap body 164 can reduce the weight of the aircraft wing and reduce the costs associated with the production of the aircraft wing and / or the aircraft. For example, forming the torque member 108 from a portion of an existing structural member 198 (e.g., a spar 106) of the wing flap 100 requires fewer joints than coupling a metal torque tube to the wing flap. As another example, forming the torque member 108 from a portion of an existing structural member 198 made of carbon fiber reduces the risk of corrosion and provides greater durability compared to a metal torque tube. As yet another example, a torque member 108 integrally formed with at least a portion of the flap body 164 is harder than a metal torque tube coupled to the wing flap, which advantageously reduces structural deflection.

[0046] Wing flap 100 is an example of an inboard flap 208 of a wing 214 of an aircraft 200, and torque component 108 is a torque component 210 ( Figure 1 In other examples, the teachings of the present disclosure may be applied to one or more other flight control surfaces 232 of aircraft 200 .

[0047] In one example, the wing flap 100 includes any suitable pivoting structure mounted to a wing body 258 of the wing 214 at the trailing edge 242 of the wing 214 or otherwise movably coupled to the wing body 258 ( Figure 1 and Figure 2 In one example, the wing flap 100 is located adjacent a wing fairing structure 220 of a fuselage 202 of an aircraft 200. During operation of the wing flap 100, the wing flap 100 can be moved between at least a raised (stowed, retracted, or "flaps up") position and a lowered (deployed, extended, or "flaps down") position to change the lift characteristics of the wing.

[0048] Reference Figure 3 , the flap body 164 includes an inboard end 124 and an outboard end 126 opposite the inboard end 124. The flap body 164 also includes a front end 112 and a rear end 116 opposite the front end 112. The torque member 108 includes an inboard end 180 and an outboard end 178 opposite the inboard end 180. In one example, the torque member 108 is integrated with the inboard end 124 of the flap body 164 and extends outwardly from the inboard end 124 of the flap body 164 in an inboard direction.

[0049] In one example, the torque member 108 is positioned toward or adjacent to the front end 112 (e.g., at or near the front end) of the flap body 164. In one example, the torque member 108 is positioned toward or adjacent to the rear end 116 of the flap body 164. In one example, the torque member 108 is located between the front end 112 and the rear end 116 of the flap body 164, such as adjacent to the middle portion of the flap body 164.

[0050] In one example, when viewed from the inboard end 124, the torque member 108 has a cross-sectional shape that at least partially matches the cross-sectional shape of the flap body 164, or matches a portion of the cross-sectional shape of the flap body 164. The cross-sectional shape of the torque member 108 that at least partially matches the cross-sectional shape of the flap body 164 at the inboard end 124 of the flap body 164 can reduce the complexity associated with coupling the torque member 108 to the flap body 164, and can reduce the impact of the torque member 108 on the aerodynamic characteristics of the wing flap 100 and / or the aircraft 200. As used herein, components having at least partially matching cross-sectional shapes can have, but do not necessarily have to have, matching sizes and / or dimensions.

[0051] In one example, the torque member 108 has a non-circular cross-sectional shape. As an example, the torque member 108 has a polygonal cross-sectional shape. In an illustrative example, the torque member 108 has a rectangular cross-sectional shape. In another illustrative example, the torque member 108 has a cross-sectional shape that includes a combination of linear sides and arcuate sides, such as three substantially linear sides and a fourth arcuate side connecting two of the linear sides to form a substantially rectangular cross-sectional shape.

[0052] In one example, the torque member 108 includes or is at least partially formed by a front wall 156, a rear wall 158 opposite the front wall 156, an upper wall 160, and a lower wall 162 opposite the upper wall 160. At least one of the front wall 156, the rear wall 158, the upper wall 160, and the lower wall 162 is integrally formed with a flap body 164. In one example, when viewed from the inboard end 124, at least one of the upper wall 160 and the lower wall 162 has a contour shape that matches a portion of the flap body 164.

[0053] The profile shape of each of the front wall 156, the rear wall 158, the upper wall 160, and the lower wall 162 defines the cross-sectional shape of the torque member 108 when viewed from the medial end 124. In one example, the profile shape of one or more of the front wall 156, the rear wall 158, the upper wall 160, and the lower wall 162 is planar. In one example, the profile shape of one or more of the front wall 156, the rear wall 158, the upper wall 160, and the lower wall 162 is curved.

[0054] Reference Figure 4, the flap body 164 of the wing flap 100 is actuated or moved between the raised and lowered positions by the torque member 108, which extends through the opening 206 formed in the fuselage 202. The opening 206 is configured so that the torque member 108 and the associated flap body 164 can move in a full range during operation. In one example, the flap actuator 260 includes a flap support mechanism 212 (also commonly referred to as a flap carriage mechanism) and an electric actuator (not shown) operably coupled to the flap support mechanism 212. In one example, the inboard end 180 of the torque member 108 is coupled to the flap support mechanism 212.

[0055] Figure 4 The wing flap 100 is shown in a generally raised position, with the torque member 108 extending through the opening 206 in the fuselage 202 and coupled to the flap support mechanism 212. In one example, the torque member 108 is configured to rotate about the rotation axis 184, or is configured to passively rotate about the rotation axis 184, to pivot or rotate the flap body 164 relative to the wing 214. Alternatively, or in addition, in one example, the torque member 108 is configured to translate forward and backward along the travel path 186, or is configured to passively translate forward and backward, to move the flap body 164 between the forward / raised position and the rearward / lowered position. In one example, the travel path 186 is arcuate, and therefore, the opening 206 is elongated and arcuate, so that the wing flap 100 (torque member 108 and the flap body 164 associated therewith) can perform a full range of motion during operation. Rotation of the torque member 108 enables the flap body 164 to pivot about the rotation axis 184 during actuation of the wing flap 100 . In one example, the rotation axis 184 is a central longitudinal axis of the torque member 108 .

[0056] In one example, the torque member 108 also includes a mounting flange 182 located at the outboard end 178 of the torque member 108 and configured to be coupled to the flap support mechanism 212. In one example, the flap support mechanism 212 includes a carrier mechanism 262, which is also commonly referred to as a carrier beam. The carrier mechanism 262 is coupled to the inboard end 180 of the torque member 108 and transmits motion to the torque member 108 during actuation of the flap support mechanism 212. In one example, the carrier mechanism 262 includes one or more link members pivotally coupled to the mounting flange 182 to enable the torque member 108 to perform rotational and translational motion in which the instantaneous center of rotation of the torque member 108 changes along the travel path 186.

[0057] refer to Figure 5In one example, the wing flap 100 includes an inboard flap fairing 190 coupled to the flap body 164 adjacent to the inboard end 124 of the flap body 164. During actuation of the wing flap 100, the inboard flap fairing 190 moves with the wing flap 100 relative to the fuselage 202. In one example, the wing flap 100 also includes a door 188 coupled to the torque member 108. The door 188 moves with the torque member 108 and is positioned relative to the fuselage 202 so that the door 188 covers the opening 206 ( Figure 4 ) at least a portion of.

[0058] refer to Figures 6 to 8 In one example, the wing flap 100 includes an upper skin 102 (the upper skin 102 is not Figure 7 and Figure 8 ), a lower skin 104 opposite the upper skin 102, and a plurality of spars 106 (also individually referred to as spars 106, collectively referred to as spars 106) extending between the upper skin 102 and the lower skin 104. In one example, a torque member 108 is integrally formed with at least one of the spars 106. In one example, the torque member 108 is integrally formed with at least one of the upper skin 102 and the lower skin 104.

[0059] In one example, the upper skin 102 and / or the lower skin 104 are permanently coupled to the respective spars 106. As an example, one or both of the upper skin 102 and the lower skin 104 may be connected to the spars 106 by various fasteners (not shown), the spars 106 may be co-cured with one or both of the upper skin 102 and / or the lower skin 104, the spars 106 may be structurally bonded (e.g., bonded) to one or both of the upper skin 102 and / or the lower skin 104, or a combination thereof.

[0060] refer to Figure 6 In one example, each of the spars 106 includes an upper spar cap 170, a lower spar cap 172 opposite the upper spar cap 170, and a spar web 174 extending between the upper spar cap 170 and the lower spar cap 172. The upper spar cap 170 is coupled to the upper skin 102, and the lower spar cap 172 is coupled to the lower skin 104. Each of the spars 106 has one of a variety of cross-sectional shapes defined by the relative configuration of the upper spar cap 170, the lower spar cap 172, and the spar web 174. In one example, at least one of the spars 106 has a constant cross-sectional shape along the longitudinal axis of the spar 106. In one example, at least one of the spars 106 has a variable or non-constant cross-sectional shape along the longitudinal axis of the spar 106.

[0061] In one example of the spar 106, one end of the spar web 174 is connected to one end of the upper spar cap 170, the other end of the spar web 174 is connected to one end of the lower spar cap 172, and both the upper spar cap 170 and the lower spar cap 172 protrude from the same side of the spar web 174 (commonly referred to as having a C-shaped or U-shaped cross-section).

[0062] In the example of the spar 106, one end of the spar web 174 is connected to the middle of the upper spar cap 170 (e.g., between the ends of the upper spar cap 170), the other end of the spar web 174 is connected to the middle of the lower spar cap 172 (e.g., between the ends of the lower spar cap 172), and both the upper spar cap 170 and the lower spar cap 172 protrude from both sides of the spar web 174 (usually having an I-shaped or H-shaped cross-section).

[0063] Reference Figure 7 and Figure 8 The torque member 108 of the disclosed wing flap 100 is at least partially formed by at least one structural member 198 ( Figure 7 ), which at least one structural member also at least partially forms a flap body 164. In one example, at least one of the spars 106 includes a spar main portion 148 and a spar extension 150 extending coaxially from the spar main portion 148. The flap body 164 is partially formed by the spar main portion 148 of at least one of the spars 106, and the torque member 108 is partially formed by the spar extension 150 of at least one of the spars 106. In one example, the spar main portion 148 and the spar extension 150 have the same cross-sectional shape and the same size. In one example, the spar main portion 148 and the spar extension 150 have different cross-sectional shapes and / or different sizes.

[0064] In one example, the spar main portion 148 extends between the outboard end 126 of the flap body 164 and the inboard end 124 of the flap body 164 in the span direction. The spar main portion 148 is a structural member or load bearing element of the flap body 164. The spar extension 150 extends from the inboard end 124 of the flap body 164 in the inboard direction. The spar extension 150 is a structural member or load bearing element of the torque member 108.

[0065] The spar main portion 148 and the spar extension portion 150 are integrally formed as a single component or piece that forms the overall structure or body of the spar 106. The spar 106 can be formed of any suitable structural material. In one example, the spar 106 is formed of a metallic material. In one example, the spar 106 is formed of a composite material. An example of a composite material is a fiber reinforced polymer, which includes a polymer matrix (e.g., a thermosetting resin or a thermoplastic polymer) reinforced with fibers (e.g., glass, carbon, aramid, etc.). For example, the composite material is a carbon fiber reinforced polymer.

[0066] In one example, at least one of the upper skin 102 and the lower skin 104 includes a skin main portion 152 and a skin extension 154 extending from the skin main portion 152. The flap body 164 is partially formed by the skin main portion 152, and the torque member 108 is partially formed by the skin extension 154.

[0067] In one example, the skin main portion 152 extends spanwise between the outboard and inboard ends 126, 124 of the flap body 164 and chordwise between the forward and aft ends 112, 116 of the flap body 164. The skin extension portion 154 extends inboard from the inboard end 124 of the flap body 164.

[0068] The skin main portion 152 and the skin extension portion 154 are integrally formed as a single component or piece that forms the entirety of the upper skin 102 and / or the lower skin 104. The upper skin 102 and / or the lower skin 104 may be formed of any suitable structural material. In one example, the upper skin 102 and / or the lower skin 104 are formed of a metal material. In one example, the upper skin 102 and / or the lower skin 104 are formed of a composite material. An example of a composite material is a fiber reinforced polymer, which includes a polymer matrix (e.g., a thermosetting resin or a thermoplastic polymer) reinforced with fibers (e.g., glass, carbon, aramid, etc.). For example, the composite material is a carbon fiber reinforced polymer.

[0069] In one example, the torque member 108 is formed by a spar extension 150 of one of the spars 106. In one example, the torque member 108 is formed by a spar extension 150 of two of the spars 106. In one example, the torque member 108 is formed by a spar extension 150 of three of the spars 106. In one example, the torque member 108 is formed by a spar extension 150 of one of the spars 106 and an extension member 146 ( Fig.14). In one example, the torque member 108 is formed by the spar extensions 150 of two of the spars 106 and the extension member 146. In one example, the torque member 108 is formed by the spar extensions 150 of two of the spars 106 and at least one extension rib 176 ( Fig.13 ). In one example, torque member 108 is formed by spar extension 150 of one of spars 106, spar extension 150, and at least one extension rib 176. In any of these examples, torque member 108 may also be formed by skin extension 154 of at least one of upper skin 102 and / or lower skin 104.

[0070] In one example, if Figure 3 As best shown in FIG. 1 , the spar extension 150 of the first spar of the spars 106 forms a front wall 156 of the torque member 108, the spar extension 150 of the second spar of the spars 106 forms a rear wall 158 of the torque member 108, the skin extension 154 of the upper skin 102 forms an upper wall 160 of the torque member 108, and the skin extension 154 of the lower skin 104 forms a lower wall 162 of the torque member 108. The spar main portion 148 (at the bottom of the first spar 106 and the second spar 106) of the spar 106 is Figure 3 The flap structure of the flap body 164 is at least partially formed by the skin extension portions 154 of the upper skin 102 and the lower skin 104 (not visible in the figure) and the flap structure of the flap body 164.

[0071] refer to Figure 8 In one example, the flap body 164 also includes additional structural elements. In one example, the flap body 164 also includes an additional spar in the spar 106 extending between the outboard end 126 and the inboard end 124 of the flap body 164. In one example, the flap body 164 also includes a plurality of ribs 166 (also referred to as ribs 166 individually) extending between the upper skin 102 and the lower skin 104. In one example, the rib 166 extends along the chord direction between each adjacent pair of spars 106.

[0072] refer to Figures 9 to 18 In one example, the plurality of spars 106 includes a front spar 110 positioned adjacent to a front end 112 of the flap body 164. In one example, the plurality of spars 106 also includes a rear spar 114 positioned adjacent to a rear end 116 of the wing flap 100. In one example, the plurality of spars 106 also includes an intermediate spar 118 located between the front spar 110 and the rear spar 114. Figures 9 to 18 In FIG. 1 , the upper skin 102 is not shown.

[0073] refer to Figures 9 to 14In the disclosed example of the wing flap 100, the front spar 110 includes a front spar main portion 120 and a front spar extension 122 extending coaxially from the front spar main portion 120 in an inboard direction. The flap body 164 is partially formed by the front spar main portion 120. The torque member 108 is partially formed by the front spar extension 122. In one example, the front spar main portion 120 extends between the inboard end 124 and the outboard end 126 of the flap body 164, and the front spar extension 122 extends between the outboard end 178 and the inboard end 180 of the torque member 108. Using the front spar 110 as a common structural member of the wing flap 100 to form the torque member 108 integrally with the flap body 164 naturally positions the torque member 108 toward or adjacent to the front end 112 of the flap body 164.

[0074] refer to Fig. 9 In one example, the wing flap 100 includes a front spar 110, an intermediate spar 118, and a rear spar 114. The flap body 164 is partially formed by the front spar main portion 120. The torque member 108 is partially formed by the front spar extension 122. In one example, the front spar main portion 120 extends between the inboard end 124 and the outboard end 126 of the flap body 164, and the front spar extension 122 extends between the outboard end 178 and the inboard end 180 of the torque member 108.

[0075] In one example, the intermediate spar 118 includes an intermediate spar main portion 132 and an intermediate spar extension portion 134 extending coaxially from the intermediate spar main portion 132 in an inboard direction. The flap body 164 is partially formed by the intermediate spar main portion 132. The torque member 108 is partially formed by the intermediate spar extension portion 134. In one example, the intermediate spar main portion 132 extends between the inboard end 124 and the outboard end 126 of the flap body 164, and the intermediate spar extension portion 134 extends between the outboard end 178 and the inboard end 180 of the torque member 108.

[0076] In one example, the rear spar 114 and / or any additional spars in the spars 106 terminate at the inboard end 124 of the flap body 164. In one example, the rear spar 114 extends between the outboard end 126 and the inboard end 124 of the flap body 164 and terminates at the inboard end 124 of the flap body 164. The flap body 164 is partially formed by the rear spar 114.

[0077] In one example, the wing flap 100 also includes one or more inboard ribs 168 (also individually referred to as inboard ribs 168) located at the inboard end 124 of the flap body 164. The inboard rib 168 is an example of one of the ribs 166 ( Figure 8). In one example, the inboard rib 168 extends between each adjacent pair of spars 106. In one example, the inboard rib 168 is positioned adjacent to the transition between the spar main portion 148 and the spar extension portion 150 of an adjacent pair of spars 106. The inboard rib 168 is configured to redistribute loads between the spars 106.

[0078] In one example, the wing flap 100 includes a first inboard rib 168 extending between and coupled to the front spar 110 and the intermediate spar 118. For example, the first inboard rib 168 has one end positioned adjacent to a transition between the front spar main portion 120 and the front spar extension portion 122 and an opposite end positioned adjacent to a transition between the intermediate spar main portion 132 and the intermediate spar extension portion 134. In one example, the wing flap 100 also includes a second inboard rib 168 extending between and coupled to the intermediate spar 118 and the rear spar 114. For example, a second one of the inboard ribs 168 has one end positioned adjacent the transition of the intermediate spar main portion 132 and the intermediate spar extension portion 134 and an opposite end positioned adjacent the terminal end of the rear spar 114 (eg, at the inboard end 124 of the flap body 164 ).

[0079] In one example, two or more of the spars 106 are parallel to each other. In one example, adjacent pairs of spars 106 are parallel to each other. As used herein, the term "parallel" has a common meaning known to those skilled in the art, and refers to a situation in which a first line extending longitudinally through one of the spars 106 and a second line extending longitudinally through another of the spars 106 share a common plane, and the first line and the second line are equidistant from each other. As used herein, the term "parallel" includes exact parallelism and approximate parallelism (i.e., close to parallelism so as to still perform a desired function or achieve a desired result).

[0080] refer to Fig.10 and Fig.11 In one example, the wing flap 100 includes a front spar 110, an intermediate spar 118, and a rear spar 114. The flap body 164 is formed in part by the front spar main portion 120 and the intermediate spar main portion 132. The torque member 108 is formed in part by the front spar extension portion 122 and the intermediate spar extension portion 134. In one example, the front spar main portion 120 and the intermediate spar main portion 132 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the front spar extension portion 122 and the intermediate spar extension portion 134 extend between the outboard end 178 and the inboard end 180 of the torque member 108.

[0081] In one example, the rear spar 114 includes a rear spar main portion 128 and a rear spar extension 130 extending coaxially from the rear spar main portion 128. The flap body 164 is partially formed by the rear spar main portion 128. The torque member 108 is partially formed by the rear spar extension 130. In one example, the rear spar main portion 128 extends between the inboard end 124 and the outboard end 126 of the flap body 164, and the rear spar extension 130 extends from the outboard end 178 of the torque member 108 to the inboard end 180.

[0082] In one example, two or more of the spars 106 are not parallel to each other. In one example, adjacent pairs of spars 106 are not parallel to each other. In one example, two or more of the spars 106 converge toward each other at (at or near) the inboard end 180 adjacent to the torque member 108. For example, at least two of the front spar 110, the middle spar 118, and the rear spar 114 converge toward each other at the inboard end 180 adjacent to the torque member 108.

[0083] In one example, the front spar 110, the intermediate spar 118, and the rear spar 114 converge toward each other at an inboard end 180 adjacent to the torque member 108. The convergence of the front spar 110, the intermediate spar 118, and the rear spar 114 toward each other reduces the distance between the front spar 110 and the intermediate spar 118 at the inboard end 124 of the flap body 164 and the inboard end 180 of the torque member 108, and reduces the distance between the intermediate spar 118 and the rear spar 114. Reducing the distance between the front spar 110 and the intermediate spar 118 can eliminate the need for an inboard rib 168 ( Fig. 9 ). Reducing the distance between the middle spar 118 and the rear spar 114 can eliminate the need for the inner rib 168 ( Fig. 9 ) needs.

[0084] refer to Fig.10 In one example, the intermediate spar 118 is oriented at an acute angle relative to a line orthogonal to and extending from the front spar 110 such that the intermediate spar 118 is pointed toward the front spar 110 adjacent the inboard end 180 of the torque member 108. The rear spar 114 is oriented at an acute angle relative to a line orthogonal to and extending from the intermediate spar 118 such that the rear spar 114 is pointed toward the intermediate spar 118 adjacent the inboard end 180 of the torque member 108.

[0085] refer to Fig.11In one example, the intermediate spar 118 is oriented at an acute angle relative to a line orthogonal to and extending from the front spar 110, such that the intermediate spar 118 is pointed toward the front spar 110 at an inboard end 180 adjacent the torque member 108. The first section 114A of the rear spar 114 is oriented parallel to the front spar 110. The second section 114B of the rear spar 114 is oriented at an acute angle relative to a line orthogonal to and extending from the intermediate spar 118, such that the second section 114B of the rear spar 114 is pointed toward the intermediate spar 118 at an inboard end 180 adjacent the torque member 108.

[0086] In one example, the spars 106 converge toward the forward end 112 of the flap body 164, as shown in FIG. Fig.10 and Fig.11 In some other examples, the spar 106 converges toward the rear end 116 of the flap body 164 .

[0087] In one example, the wing flap 100 includes a front spar 110, an intermediate spar 118, and a rear spar 114. The flap body 164 is partially formed by the front spar main portion 120, the intermediate spar 118, and the rear spar main portion 128. The torque member 108 is partially formed by the front spar extension 122 and the rear spar extension 130. In one example, the front spar main portion 120, the intermediate spar 118, and the rear spar main portion 128 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the front spar extension 122 and the rear spar extension 130 extend between the outboard end 178 and the inboard end 180 of the torque member 108. The front spar 110 and the rear spar 114 converge toward each other adjacent to the inboard end 180 of the torque member 108. The front and rear spar 110 , 114 converging toward each other reduces the distance between the front and rear spar 110 , 114 at the inboard end 124 of the flap body 164 and the inboard end 180 of the torque member 108 .

[0088] In one example, the wing flap 100 includes a front spar 110 and a rear spar 114. The flap body 164 is formed in part by the front spar main portion 120 and the rear spar main portion 128. The torque member 108 is formed in part by the front spar extension portion 122 and the rear spar extension portion 130. In one example, the front spar main portion 120 and the rear spar main portion 128 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the front spar extension portion 122 and the rear spar extension portion 130 extend between the outboard end 178 and the inboard end 180 of the torque member 108. The front spar 110 and the rear spar 114 converge toward each other adjacent to the inboard end 180 of the torque member 108. The front and rear spar 110 , 114 converging toward each other reduces the distance between the front and rear spar 110 , 114 at the inboard end 124 of the flap body 164 and the inboard end 180 of the torque member 108 .

[0089] refer to Fig.12 In one example, the wing flap 100 includes a front spar 110, an intermediate spar 118, and a rear spar 114. The flap body 164 is partially formed by the front spar main portion 120, the intermediate spar main portion 132, and the rear spar 114. The torque member 108 is partially formed by the front spar extension 122 and the intermediate spar extension 134. In one example, the front spar main portion 120, the intermediate spar main portion 132, and the rear spar 114 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the front spar extension 122 and the intermediate spar extension 134 extend between the outboard end 178 and the inboard end 180 of the torque member 108.

[0090] In one example, wing flap 100 also includes an extension member 146 coupled to flap body 164 and located between front spar extension 122 of front spar 110 and intermediate spar extension 134 of intermediate spar 118. Torque member 108 is formed in part by extension member 146.

[0091] In one example, the extension member 146 extends outwardly in an inboard direction from the inboard end 124 of the flap body 164 to the inboard end 180 of the torque member 108. The extension member 146 extends outwardly in an inboard direction from the inboard end 124 of the flap body 164 to the inboard end 180 of the torque member 108. Figure 1 ) is coupled to flap body 164 in any suitable manner that is transferred to flap body 164 via torque member 108 .

[0092] In one example, the extension member 146 is coupled to an inner rib 168, which extends between and is coupled to the front spar 110 and the intermediate spar 118. In one example, the inner rib 168 includes a reinforcement or flange that is vertically oriented and located on the inner surface of the inner rib 168. The extension member 146 is fastened (e.g., bolted) to the reinforcement of the inner rib 168. Any other suitable joint can be used to couple the outboard end of the extension member 146 to the inner rib 168. The extension member 146 and the inner rib 168 can be formed of any suitable structural material. In one example, one or both of the extension member 146 and the inner rib 168 are formed of a metal material. In one example, one or both of the extension member 146 and the inner rib 168 are formed of a composite material (e.g., a carbon fiber reinforced polymer).

[0093] refer to Fig.13 In one example, the wing flap 100 includes a front spar 110, an intermediate spar 118, and a rear spar 114. The flap body 164 is partially formed by the front spar main portion 120, the intermediate spar main portion 132, and the rear spar 114. The torque member 108 is partially formed by the front spar extension 122 and the intermediate spar extension 134. In one example, the front spar main portion 120, the intermediate spar main portion 132, and the rear spar 114 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the front spar extension 122 and the intermediate spar extension 134 extend between the outboard end 178 and the inboard end 180 of the torque member 108.

[0094] In one example, the wing flap 100 further includes an extension rib 176 extending between and coupled to the front spar extension 122 of the front spar 110 and the intermediate spar extension 134 of the intermediate spar 118. The torque member 108 is formed in part by the extension rib 176.

[0095] In one example, the extension rib 176 is located at any of a variety of locations between the outboard end 178 and the inboard end 180 of the torque member 108. The extension rib 176 is configured to redistribute loads between the front spar extension 122 of the front spar 110 and the intermediate spar extension 134 of the intermediate spar 118 during actuation of the wing flap 100. In one example, the extension rib 176 extends between and / or is coupled to the upper skin 102 and / or the lower skin 104.

[0096] In one example, the wing flap 100 includes a plurality of extension ribs 176 such as Fig.13As shown. In one example, the extension ribs 176 are equally spaced along the torque member 108 between the outboard end 178 and the inboard end 180 of the torque member 108. The number of extension ribs 176 can vary depending on, for example, the load applied to the torque member 108, the fault protection requirements of the torque member 108, and the required stiffness of the torque member 108. In one example, one of the extension ribs 176 is positioned adjacent to the inboard end 180 of the torque member 108. In one example, at least another of the extension ribs 176 is located between the outboard end 178 and the inboard end 180 of the torque member 108, such as between one of the extension ribs 176 located at the inboard end 180 of the torque member 108 and the inboard rib 168.

[0097] refer to Fig.14 In one example, the wing flap 100 includes a front spar 110 and a rear spar 114. The flap body 164 is partially formed by the front spar main portion 120 and the rear spar 114. The torque member 108 is partially formed by the front spar extension 122. In one example, the front spar main portion 120 and the rear spar 114 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the front spar extension 122 extends between the outboard end 178 and the inboard end 180 of the torque member 108.

[0098] In one example, the wing flap 100 further includes an inboard rib 168 extending between the front spar 110 and the rear spar 114 at the inboard end 124 of the flap body 164. In one example, the wing flap 100 further includes an extension member 146 coupled to the inboard rib 168. The torque member 108 is formed in part by the extension member 146.

[0099] Although Fig.14 1. In one example, the wing flap 100 further includes at least one extension rib 176 ( Fig.13 ), the extension rib 176 extends between the front spar extension portion 122 of the front spar 110 and the extension member 146. The torque member 108 is partially formed by the extension rib 176 and the extension member 146.

[0100] refer to Figures 15 to 18In the disclosed example of the wing flap 100, the rear spar 114 includes a rear spar main portion 128 and a rear spar extension 130 extending coaxially from the rear spar main portion 128 in an inboard direction. The flap body 164 is partially formed by the rear spar main portion 128. The torque member 108 is partially formed by the rear spar extension 130. In one example, the rear spar main portion 128 extends between the inboard end 124 and the outboard end 126 of the flap body 164, and the rear spar extension 130 extends between the outboard end 178 and the inboard end 180 of the torque member 108. Using the rear spar 114 as a common structural member of the wing flap 100 to form the torque member 108 and the flap body 164 naturally positions the torque member 108 toward or adjacent to the rear end 116 of the flap body 164.

[0101] refer to Fig.15 In one example, the wing flap 100 includes a front spar 110, an intermediate spar 118, and a rear spar 114. The flap body 164 is partially formed by the rear spar main portion 128. The torque member 108 is partially formed by the rear spar extension 130. In one example, the rear spar main portion 128 extends between the inboard end 124 and the outboard end 126 of the flap body 164, and the rear spar extension 130 extends between the outboard end 178 and the inboard end 180 of the torque member 108.

[0102] In one example, the intermediate spar 118 includes an intermediate spar main portion 132 and an intermediate spar extension portion 134 extending coaxially from the intermediate spar main portion 132 in an inboard direction. The flap body 164 is partially formed by the intermediate spar main portion 132. The torque member 108 is partially formed by the intermediate spar extension portion 134. In one example, the intermediate spar main portion 132 extends between the inboard end 124 and the outboard end 126 of the flap body 164, and the intermediate spar extension portion 134 extends between the outboard end 178 and the inboard end 180 of the torque member 108.

[0103] In one example, the front spar 110 and / or any additional spars in the spars 106 terminate at the inboard end 124 of the flap body 164. In one example, the front spar 110 extends between the outboard end 126 and the inboard end 124 of the flap body 164 and terminates at the inboard end 124 of the flap body 164. The flap body 164 is partially formed by the front spar 110.

[0104] In one example, the wing flap 100 further includes one or more of the inboard ribs 168 located at the inboard end 124 of the flap body 164. In one example, the wing flap 100 includes a first inboard rib of the inboard ribs 168 extending between and coupled to the rear spar 114 and the intermediate spar 118. For example, the first inboard rib of the inboard ribs 168 has one end positioned adjacent to the transition of the rear spar main portion 128 and the rear spar extension 130 and an opposite end positioned adjacent to the transition of the intermediate spar main portion 132 and the intermediate spar extension 134. In one example, the wing flap 100 further includes a second inboard rib of the inboard ribs 168 extending between and coupled to the intermediate spar 118 and the front spar 110. For example, a second one of the inboard ribs 168 has one end positioned adjacent the transition of the intermediate spar main portion 132 and the intermediate spar extension portion 134 and an opposite end positioned adjacent the terminal end of the front spar 110 (eg, at the inboard end 124 of the flap body 164 ).

[0105] refer to Fig.16 In one example, the wing flap 100 includes a front spar 110, an intermediate spar 118, and a rear spar 114. The flap body 164 is partially formed by the rear spar main portion 128, the intermediate spar main portion 132, and the front spar 110. The torque member 108 is partially formed by the rear spar extension 130 and the intermediate spar extension 134. In one example, the rear spar main portion 128, the intermediate spar main portion 132, and the front spar 110 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the rear spar extension 130 and the intermediate spar extension 134 extend between the outboard end 178 and the inboard end 180 of the torque member 108.

[0106] In one example, wing flap 100 also includes an extension member 146 coupled to flap body 164 and located between rear spar extension 130 of rear spar 114 and intermediate spar extension 134 of intermediate spar 118. Torque member 108 is formed in part by extension member 146.

[0107] In one example, the extension member 146 extends outwardly in an inboard direction from the inboard end 124 of the flap body 164 to the inboard end 180 of the torque member 108. In one example, the extension member 146 is coupled to the inboard rib 168, which extends between and is coupled to the rear spar 114 and the intermediate spar 118. The extension member 146 is sufficient to transfer the actuation force from the flap support mechanism 212 ( Figure 1) is coupled to flap body 164 in any suitable manner that is transferred to flap body 164 via torque member 108 .

[0108] refer to Fig.17 In one example, the wing flap 100 includes a front spar 110, an intermediate spar 118, and a rear spar 114. The flap body 164 is partially formed by the rear spar main portion 128, the intermediate spar main portion 132, and the front spar 110. The torque member 108 is partially formed by the rear spar extension 130 and the intermediate spar extension 134. In one example, the rear spar main portion 128, the intermediate spar main portion 132, and the front spar 110 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the rear spar extension 130 and the intermediate spar extension 134 extend between the outboard end 178 and the inboard end 180 of the torque member 108.

[0109] In one example, the wing flap 100 also includes an extension rib 176 that extends between and is coupled to the rear spar extension 130 of the rear spar 114 and the intermediate spar extension 134 of the intermediate spar 118. The torque member 108 is formed in part by the extension rib 176.

[0110] In one example, the extension ribs 176 are located at any of a variety of locations between the outboard end 178 and the inboard end 180 of the torque member 108. The extension ribs 176 are configured to redistribute loads between the rear spar extension 130 of the rear spar 114 and the intermediate spar extension 134 of the intermediate spar 118 during actuation of the wing flap 100. In one example, the wing flap 100 includes a plurality of extension ribs 176, such as Fig.17 In one example, the extension ribs 176 are equally spaced apart along the torque member 108 between the outboard end 178 and the inboard end 180 of the torque member 108 .

[0111] refer to Fig.18 In one example, the wing flap 100 includes a front spar 110 and a rear spar 114. The flap body 164 is partially formed by the rear spar main portion 128 and the front spar 110. The torque member 108 is partially formed by the rear spar extension 130. In one example, the rear spar main portion 128 and the front spar 110 extend between the inboard end 124 and the outboard end 126 of the flap body 164, and the rear spar extension 130 extends between the outboard end 178 and the inboard end 180 of the torque member 108.

[0112] In one example, the wing flap 100 further includes an inboard rib 168 extending between the front spar 110 and the rear spar 114 at the inboard end 124 of the flap body 164. In one example, the wing flap 100 further includes an extension member 146 coupled to the inboard rib 168. The torque member 108 is formed in part by the extension member 146.

[0113] Although Fig.18 1. In one example, the wing flap 100 further includes at least one extension rib 176 ( Fig.17 ), the extension rib 176 extends between the rear spar extension portion 130 of the rear spar 114 and the extension member 146. The torque member 108 is partially formed by the extension rib 176 and the extension member 146.

[0114] exist Fig. 9 , Fig.12 and Fig.13 In the example shown in FIG. 1 , the front spar extension 122 of the front spar 110 forms the front wall 156 ( Figure 3 ), the intermediate spar extension 134 of the intermediate spar 118 forms the rear wall 158 of the torque member 108 ( Figure 3 ).exist Fig.10 and Fig.11 In the example shown, the front spar extension 122 of the front spar 110 forms a front wall 156 of the torque member 108, and the rear spar extension 130 of the rear spar 114 forms a rear wall 158 of the torque member 108. Fig.14 In the example shown, the front spar extension 122 of the front spar 110 forms a front wall 156 of the torque member 108 , and the extension member 146 forms a rear wall 158 of the torque member 108 .

[0115] exist Figures 15 to 17 In the example shown, the rear spar extension 130 of the rear spar 114 forms the rear wall 158 ( Figure 3 ), the intermediate spar extension 134 of the intermediate spar 118 forms the front wall 156 of the torque member 108 ( Figure 3 ).exist Fig.18 In the example shown, the rear spar extension 130 of the rear spar 114 forms a rear wall 158 of the torque member 108 , and the extension member 146 forms a front wall 156 of the torque member 108 .

[0116] exist Figures 9 to 18 In the example shown, the skin extension 154 (not visible) of the upper skin 102, also referred to as the upper skin extension, forms the upper wall 160 ( Figure 3), the skin extension 154 of the lower skin 104 is also referred to as the lower skin extension, which forms the lower wall 162 of the torque member 108. The skin main part 152 of the upper skin 102 is also referred to as the upper skin main part, which forms the upper skin panel of the flap body 164, and the skin main part 152 of the lower skin 104 is also referred to as the lower skin main part, which forms the lower skin panel of the flap body 164.

[0117] refer to Fig.19 In one example, one or both of the upper skin 102 and / or the lower skin 104 only partially forms the flap body 164. In one example, one or both of the upper skin 102 and / or the lower skin 104 extend between the outboard end 126 and the inboard end 124 of the flap body 164 and terminate at the inboard end 124 of the flap body 164.

[0118] In one example, the wing flap 100 also includes an upper skin extension member 194 in place of the upper skin extension. In one example, the upper skin extension member 194 extends between the inboard end 180 and the outboard end 178 of the torque member 108 and is coupled to the spar extension 150 and the extension member 146 of at least one of the spars 106 (e.g., an adjacent pair of spars 106 or a spar 106). The torque member 108 is partially formed by the upper skin extension member 194.

[0119] In one example, the wing flap 100 also includes a lower skin extension member 196 in place of the lower skin extension. In one example, the lower skin extension member 196 extends between the inboard end 180 and the outboard end 178 of the torque member 108 and is coupled to the spar extension 150 and the extension member 146 of at least one of the spars 106 (e.g., an adjacent pair of spars 106 or a spars 106). The torque member 108 is partially formed by the lower skin extension member 196.

[0120] In the illustrated example, the skin extensions 154, upper skin extension members 194, and lower skin extension members 196 of the upper skin 102 and lower skin 104 extend all the way to and terminate at the inboard end 180 of the torque member 108. In other examples, one or more of the skin extensions 154, upper skin extension members 194, and / or lower skin extension members 196 of the upper skin 102 and lower skin 104 terminate before the inboard end 180 of the torque member 108. In one example, the skin extensions 154, upper skin extension members 194, and / or lower skin extension members 196 of the upper skin 102 and lower skin 104 extend to at least a point on the torque member 108 where the torque member 108 enters the fuselage 202 (through the opening 206). Figure 4 ).

[0121] In some aerospace implementations, failsafe measures may be beneficial to ensure continued safe flight and landing. One example of a failsafe measure is having a redundant load path that is not used until a primary load path fails. Another example of a failsafe measure is having two or more load paths where a failure in any one load path redistributes the load to another load path, each load path being able to react to the entire load. Another example of a failsafe measure is having sufficient reserve load capacity in each structural member defining a given load path so that the load path is able to react to the entire load after a failure, damage, or other impairment of one of the structural members occurs.

[0122] In some examples, such as Figures 10 to 12 and Fig.16 In the illustrated example, the torque member 108 of the disclosed wing flap 100 includes a failsafe configuration. In one example, the spar extensions 150 of two adjacent spars 106 can form a redundant load path. In one example, the extension member 146 and the spar extensions 150 of the adjacent spars 106 can form a redundant load path. In one example ( Fig.10 and 11 ), front spar extension 122 and middle spar extension 134 define a first load path, middle spar extension 134 and rear spar extension 130 define a second load path, and front spar extension 122 and rear spar extension 130 define a third load path. In one example ( Fig.12 ), the front spar extension 122 and the extension member 146 define a first load path, the extension member 146 and the rear spar extension 130 define a second load path, and the front spar extension 122 and the rear spar extension 130 define a third load path. In one example ( Fig.16 ), the middle spar extension 134 and the extension member 146 define a first load path, the extension member 146 and the rear spar extension 130 define a second load path, and the middle spar extension 134 and the rear spar extension 130 define a third load path. In these examples, each of the load paths is capable of reacting to the entire load applied to the wing flap 100, and a failure of one of the load paths (e.g., caused by damage to one of the spars 106) can be redistributed to another load path. In one example, one of the redundant load paths is loaded, while the other of the redundant load paths is not loaded. When a loaded load path fails, the load is distributed to the unloaded load path. In one example, each of the redundant load paths is loaded, and any of the loaded load paths is capable of reacting to the entire load when the other fails.

[0123] In some examples, such as Fig. 9 , Figures 13 to 15 , Fig.17 and Fig.18 In the illustrative example shown, the torque member 108 of the disclosed wing flap 100 may also include a failsafe configuration. In one example, the spar extension 150 of each of the spars 106 has a reserve load capacity that exceeds the total load applied to the wing flap 100. In one example, the spar extension 150 and the extension member 146 of the spar 106 each have a reserve load capacity that exceeds the total load applied to the wing flap 100. In one example ( Fig. 9 and Fig.13 ), the front spar extension 122 and the middle spar extension 134 define a load path, and each of the front spar extension 122 and the middle spar extension 134 has a reserve load capacity exceeding the entire load applied to the wing flap 100. In one example ( Fig.15 and Fig.17 ), the middle spar extension 134 and the rear spar extension 130 define a load path, and each of the middle spar extension 134 and the rear spar extension 130 has a reserve load capacity exceeding the entire load applied to the wing flap 100. In one example ( Fig.14 ), the front spar extension 122 and the extension member 146 define a load path, and each of the front spar extension 122 and the extension member 146 has a reserve load capacity exceeding the entire load applied to the wing flap 100. In one example ( Fig.18 ), the rear spar extension 130 and the extension member 146 define a load path, and each of the rear spar extension 130 and the extension member 146 has a reserve load capacity that exceeds the entire load applied to the wing flap 100.

[0124] refer to Fig. 20 , an exemplary method 1000 is also disclosed. In one example, the method 1000 is used to form a wing flap 100. In one example, the method 1000 includes a step (block 1002) of integrally forming a torque member 108 with at least a portion of a flap body 164 to form the wing flap 100. The flap body 164 is configured to be movably coupled to a wing 214 of an aircraft 200. The torque member 108 is configured to be operably coupled to a flap actuator 260 of the aircraft 200.

[0125] In one example, the method 1000 includes the step of providing a lower skin 104, an upper skin 102, and a plurality of spars 106 (block 1004). As used herein, the term "providing" does not require any specific delivery or receipt of the provided items. Rather, the term "providing" is used to refer to an item that is usable or in a state or condition ready for use. At least one of the plurality of spars 106 includes a spar main portion 148 and a spar extension portion 150 extending from the spar main portion 148.

[0126] In one example, method 1000 includes the step of bonding together lower skin 104, upper skin 102, and plurality of spars 106 (block 1006). Various methods or operations may be used to bond lower skin 104, upper skin 102, and plurality of spars 106, including but not limited to fastening, co-curing, bonding, or a combination thereof.

[0127] In one example, the method 1000 includes the steps of partially forming the flap body 164 with the spar main portion 148 of a first spar in the plurality of spars 106 (block 1008 ), and partially forming the torque member 108 with the spar extension portion 105 of the first spar in the plurality of spars 106 (block 1010 ).

[0128] In one example, the method 1000 includes the steps of partially forming the flap body 164 with the spar main portion 148 of the second spar in the plurality of spars 106 (block 1012), and partially forming the torque member 108 with the spar extension 150 of the second spar in the plurality of spars 106 (block 1014). Alternatively, the method 10000 includes the steps of partially forming the flap body 164 with the third spar in the plurality of spars 106 (block 1016), and partially forming the torque member 108 with the extension member 146 coupled to the flap body 164 (block 1018). In one example, the method 1000 includes the steps of partially forming the flap body 164 with the fourth spar in the plurality of spars 106 (block 1020).

[0129] In one example, the method 1000 includes the steps of partially forming the flap body 164 with the skin main portion 152 of the upper skin 102 (block 1022), and partially forming the torque member 108 with the skin extension portion 154 of the upper skin 102 (block 1024). Alternatively, the method 1000 includes the steps of partially forming the flap body 164 with the upper skin 102 (block 1026), and partially forming the torque member 108 with the upper skin extension member 194 (block 1028).

[0130] In one example, the method 1000 includes the steps of partially forming the flap body 164 with the skin main portion 152 of the lower skin 104 (block 1030), and partially forming the torque member 108 with the skin extension portion 154 of the lower skin 104 (block 1032). Alternatively, the method 1000 includes the steps of partially forming the flap body 164 with the lower skin 104 (block 1034), and partially forming the torque member 108 with the lower skin extension member 196 (block 1036).

[0131] In one example, the method 1000 is further used to form the wing 214 of the aircraft 200. In one example, the method 1000 includes the following steps: the flap body 164 of the wing flap 100 is movably coupled to the wing body 258 of the wing 214 at the trailing edge 242 of the wing 214 (block 1038). According to the method 1000, the wing flap 100 can be coupled to the wing 214 during the manufacturing process of the wing 214. Alternatively, according to the method 1000, the conventional inboard flap of the aircraft 200 can be replaced with the wing flap 100, for example, during the maintenance or repair of the aircraft 200.

[0132] In one example, the method 1000 is further used to form an aircraft 200. In one example, the method 1000 includes the step of coupling the wing 214 to the fuselage 202 of the aircraft 200 (block 1040). In one example, the method 1000 includes the step of operably coupling the inboard end 180 of the torque member 108 to the flap actuator 260 (block 1042). In one example, the torque member 108 extends into the fuselage 202 through the opening 206 in the fuselage 202.

[0133] In one example, method 1000 is also used to operate wing flap 100. In one example, method 1000 includes the following steps: actuating wing flap 100 between raised position and lowered position (block 1044). In one example, flap actuator 260 pivots and / or translates flap body 164 of wing flap 100 relative to wing 214 via torque member 108.

[0134] Examples of the wing flap 100 and method 1000 disclosed herein may find use in a variety of potential applications, particularly in the transportation industry, including, for example, aerospace applications. Figure 1 and Fig.21 Examples of the wing flap 100 and method 1000 may be found in Fig.21 Aircraft manufacturing and service method 1100 and the like are shown in the flowchart Figure 1The wing flap 100 is shown in use in an aircraft 200 . The disclosed example aircraft applications may include forming the wing flap 100 and using the wing flap 100 as a flight control surface for the aircraft 200 .

[0135] like Fig.21 As shown, during pre-production, the exemplary method 1100 may include the specification and design of the aircraft 200 (block 1102) and the procurement of materials (block 1104). During the production process of the aircraft 200, the components and subassemblies of the aircraft 200 may be manufactured (block 1106) and system integration (block 1108). Thereafter, the aircraft 200 may be put into service (block 1112) after certification and delivery (block 1110). The disclosed wing flap 100 and method 1000 may form part of the components and subassembly manufacturing (block 1106) and / or system integration (block 1108). Routine maintenance and repair (block 1114) may include modifying, reconfiguring, refurbishing one or more systems of the aircraft 200, etc., such as repairing and / or replacing the inner wing flap.

[0136] Each of the processes of the illustrative method can be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, a leasing company, a military entity, a service organization, and the like.

[0137] Examples of wing flaps 100 and methods 1000 shown or described herein may be found at Fig.21 Any one or more stages of the manufacturing and maintenance method 1100 shown in the flowchart shown are used. For example, a component or subassembly corresponding to the component and subassembly manufacturing (block 1106), such as the wing flap 100 or the wing 214, can be processed or manufactured in a manner similar to the component or subassembly produced when the aircraft 200 is in operation (block 1112). In addition, one or more examples of the wing flap 100, the method 1000, or a combination thereof can be used during system integration (block 1108) and / or certification and delivery (block 1110). Similarly, one or more examples of the wing flap 100, the method 1000, or a combination thereof can be used, for example but not limited to, during the operation (block 1112) and maintenance and repair (block 1114) of the aircraft 200.

[0138] Although the example of aerospace is shown, the principles disclosed herein can be applied to other industries, such as the automotive industry. Therefore, in addition to aircraft, the principles disclosed herein can also be applied to other vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.).

[0139] The present disclosure further includes the following illustrative, non-exhaustive list of examples, which may or may not be claimed:

[0140] 1. A wing flap 100, comprising:

[0141] a flap body 164; and

[0142] The torque member 210 is formed integrally with at least a portion of the flap body 164 .

[0143] 2. The wing flap 100 of Example 1, wherein the torque member 210 has a non-circular cross-sectional shape.

[0144] 3. The wing flap 100 of example 1 or 2, further comprising:

[0145] Upper skin 102;

[0146] A lower skin 104, opposite to the upper skin 102; and

[0147] A plurality of spars 106 extending between the upper skin 102 and the lower skin 104,

[0148] The torque member 210 is integrally formed with at least one of the plurality of spars 106 .

[0149] 4. The wing flap 100 of Example 3, wherein:

[0150] At least one of the plurality of spars 106 includes a spar main portion 148 and a spar extension portion 150 extending from the spar main portion 148;

[0151] The flap body 164 is formed in part by the spar main portion 148 , and the torque member 210 is formed in part by the spar extension portion 150 .

[0152] 5. The wing flap 100 of example 3 or 4, wherein the torque member 210 is formed integrally with at least one of the upper skin 102 and the lower skin 104 .

[0153] 6. The wing flap 100 of any one of Examples 3 to 5, wherein:

[0154] The plurality of spars 106 include a front spar 110 including a front spar main portion 120 and a front spar extension portion 122 extending from the front spar main portion 120;

[0155] The flap body 164 is formed in part by the front spar main portion 120; and

[0156] The torque member 210 is formed in part by the front spar extension 122 .

[0157] 7. The wing flap 100 of Example 6, wherein:

[0158] The plurality of spars 106 further include an intermediate spar 118 including an intermediate spar main portion 132 and an intermediate spar extension portion 134 extending from the intermediate spar main portion 132;

[0159] The flap body 164 is formed in part by the intermediate spar main portion 132;

[0160] and

[0161] The torque member 210 is formed in part by the intermediate spar extension 134 .

[0162] 8. The wing flap 100 of Example 7, wherein:

[0163] The plurality of spars 106 further includes a rear spar 114 including a rear spar main portion 128 and a rear spar extension portion 130 extending from the rear spar main portion 128;

[0164] The flap body 164 is formed in part by the rear spar main portion 128; and

[0165] The torque member 210 is formed in part by the rear spar extension 130 .

[0166] 9. The wing flap 100 of Example 8, wherein at least two of the front spar 110 , the intermediate spar 118 , and the rear spar 114 converge toward each other at an inboard end adjacent the torque member 210 .

[0167] 10. The wing flap 100 of example 7 or 8, further comprising an extension member 146 coupled to the flap body 164 and located between the front spar extension portion 122 of the front spar 110 and the intermediate spar extension portion 134 of the intermediate spar 118 , and wherein the torque member 210 is partially formed by the extension member 146 .

[0168] 11. The wing flap 100 of any one of Examples 7 to 10, further comprising an extension rib 176 extending between the front spar extension portion 122 of the front spar 110 and the intermediate spar extension portion 134 of the intermediate spar 118 , and wherein the torque member 210 is partially formed by the extension rib 176 .

[0169] 12. The wing flap 100 of any one of Examples 6 to 11, wherein:

[0170] The plurality of spars 106 include a rear spar 114;

[0171] The wing flap 100 further includes: an inboard rib 168 extending between the front spar 110 and the rear spar 114 at the inboard end of the flap body 164; and an extension member 146 coupled to the inboard rib 168;

[0172] The flap body 164 is formed in part by the rear spar 114; and

[0173] The torque member 210 is formed in part by the extension member 146 .

[0174] 13. The wing flap 100 of any one of Examples 3 to 12, wherein:

[0175] The plurality of spars 106 include a rear spar 114 including a rear spar main portion 128 and a rear spar extension 130 extending from the rear spar main portion 128;

[0176] The flap body 164 is formed in part by the rear spar main portion 128; and

[0177] The torque member 210 is formed in part by the rear spar extension 130 .

[0178] 14. The wing flap 100 of example 13, wherein:

[0179] The plurality of spars 106 further include an intermediate spar 118 including an intermediate spar main portion 132 and an intermediate spar extension portion 134 extending from the intermediate spar main portion 132;

[0180] The flap body 164 is formed in part by the intermediate spar main portion 132;

[0181] and

[0182] The torque member 210 is formed in part by the intermediate spar extension 134 .

[0183] 15. The wing flap 100 of Example 14 further includes an extension member 146 connected to the flap body 164 and located between the rear spar extension portion 130 of the rear spar 114 and the intermediate spar extension portion 134 of the intermediate spar 118, and wherein the torque member 210 is partially formed by the extension member 146.

[0184] 16. The wing flap 100 of example 14 or 15, further comprising an extension rib 176 extending between the rear spar extension portion 130 of the rear spar 114 and the intermediate spar extension portion 134 of the intermediate spar 118 , and wherein the torque member 210 is partially formed by the extension rib 176 .

[0185] 17. The wing flap 100 of any one of Examples 13 to 16, wherein:

[0186] The plurality of spars 106 include a front spar 110;

[0187] The wing flap 100 further includes: an inboard rib 168 extending between the front spar 110 and the rear spar 114 at the inboard end of the flap body 164; and an extension member 146 coupled to the inboard rib 168;

[0188] The flap body 164 is formed in part by the front spar 110; and

[0189] The torque member 210 is formed in part by the extension member 146 .

[0190] 18. A wing of an aircraft, the wing comprising:

[0191] a wing body 258; and

[0192] The wing flap 100 includes: a flap body 164 movably coupled to the wing body 258 ; and a torque member 210 integrally formed with at least a portion of the flap body 164 .

[0193] 19. The wing of Example 18, wherein:

[0194] The wing flap 100 further includes: an upper skin 102; a lower skin 104, opposite to the upper skin 102; and a plurality of spars 106, extending between the upper skin 102 and the lower skin 104; and

[0195] The torque member 210 is integrally formed with at least one of the plurality of spars 106 .

[0196] 20. A method for forming a wing flap 100, the method comprising:

[0197] The torque member 210 is integrally formed with at least a portion of the flap body 164 to form the wing flap 100 , wherein:

[0198] The flap body 164 is configured to be movably coupled to a wing of an aircraft; and

[0199] The torque member 210 is configured to be coupled to a flap actuator 260 of the aircraft.

[0200] The "example" mentioned here means that one or more features, structures, elements, components, characteristics and / or operating steps described in conjunction with the example are included in at least one embodiment and / or specific implementation of the subject matter of the present disclosure. Therefore, the phrase "example" and similar language throughout the present disclosure may but do not necessarily refer to the same example. Further, the subject matter representing any one example may but does not necessarily include the subject matter representing any other example.

[0201] As used herein, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specific function is actually capable of performing the specific function without any changes, rather than just having the potential to perform the specific function after further modification. In other words, a system, device, structure, article, element, component, or hardware that is "configured to" perform a specific function is specifically selected, created, implemented, utilized, programmed, and / or designed to perform the specific function. As used herein, "configured to" means an existing feature of a system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform the specific function without further modification. For the purposes of this disclosure, a system, device, structure, article, element, component, or hardware that is described as "configured to" perform a specific function may be additionally or alternatively described as "suitable for" and / or "operably" perform the function.

[0202] Unless otherwise indicated, the terms "first," "second," etc. are used herein merely as labels and are not intended to impose an order, position, or hierarchy on the items to which these terms refer. Furthermore, reference to a "second" item does not require or preclude the presence of lower-numbered items (e.g., a "first" item) and / or higher-numbered items (e.g., a "third" item).

[0203] As used herein, "coupled," "coupled to," and similar terms refer to two or more elements that are joined, linked, fastened, connected, communicated, or otherwise associated (e.g., mechanically, electrically, fluidically, optically, electromagnetically) with one another. In various examples, the elements may be associated directly or indirectly. For example, element A may be directly associated with element B. As another example, element A may be indirectly associated with element B, for example, via another element C. It should be understood that not all associations between the various disclosed elements are necessarily represented. Therefore, there may be connections other than those shown in the figures.

[0204] As used herein, the phrase "at least one of," when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, "at least one of item A, item B, and item C" may include, but is not limited to, item A or item A and item B. This example may also include item A, item B, and item C, or item B and item C. In other examples, "at least one of" may be, for example but not limited to, two of item A, one of item B, and ten of item C; four of item B and seven of item C; and other suitable combinations.

[0205] exist Fig. 20 and Fig.21 In the present invention, as described above, block diagrams can represent operations and / or parts thereof, and the lines connecting the various block diagrams do not imply any particular order or subordination of the operations or parts thereof. Block diagrams represented by dashed lines represent optional operations and / or parts thereof. The dashed lines connecting the various block diagrams (if any) represent optional subordination of operations or parts thereof. It should be understood that not all subordination between the various disclosed operations must be represented. Fig. 20 and Fig.21 The attached disclosure describing the operation of the disclosed method described herein should not be interpreted as necessarily determining the order in which the operations are performed. On the contrary, although an exemplary order is shown, it should be understood that the order of operations can be modified when appropriate. Therefore, the operations shown can be modified, added and / or omitted, and some operations can be performed in different orders or simultaneously. In addition, it will be understood by those skilled in the art that not all described operations need to be performed.

[0206] Although various embodiments and / or examples of the disclosed antenna, aerospace vehicle, and method have been shown and described, modifications may occur to those skilled in the art after reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

Claims

1. A wing flap (100) for a wing of an aircraft, the wing flap (100) comprising: Flap body (164); as well as a torque member (108) formed integrally with at least a portion of the flap body (164); Upper skin (102); A lower skin (104), opposite to the upper skin (102); as well as A plurality of spars (106) extending between the upper skin (102) and the lower skin (104), wherein the torque member (108) is integrally formed with at least one wing spar of the plurality of wing spars (106); At least one spar of the plurality of spars (106) includes a spar main portion (148) and a spar extension portion (150) extending from the spar main portion (148); The flap body (164) is partially formed by the spar main portion (148); The torque member (108) is formed in part by the spar extension (150); The flap body (164) includes an inner end (124), an outer end (126) opposite to the inner end (124), a front end (112), and a rear end (116) opposite to the front end (112); The torque member (108) includes an inner end (180) and an outer end (178) opposite the inner end (180); and The torque member (108) is integral with the inboard end (124) of the flap body (164) and extends from the inboard end (124) of the flap body (164) in an inboard direction.

2. The wing flap (100) of claim 1, wherein the torque member (108) has a non-circular cross-sectional shape.

3. The wing flap (100) of claim 1, wherein the torque member (108) is integrally formed with at least one of the upper skin (102) and the lower skin (104).

4. The wing flap (100) according to claim 1, wherein: The plurality of spars (106) include a front spar (110), the front spar (110) including a front spar main portion (120) and a front spar extension portion (122) extending from the front spar main portion (120); The flap body (164) is formed in part by the front spar main portion (120); and The torque member (108) is formed in part by the front spar extension (122).

5. The wing flap (100) according to claim 4, wherein: The plurality of spars (106) further include an intermediate spar (118), the intermediate spar (118) including an intermediate spar main portion (132) and an intermediate spar extension portion (134) extending from the intermediate spar main portion (132); The flap body (164) is formed in part by the intermediate spar main portion (132); and The torque member (108) is formed in part by the intermediate spar extension (134).

6. The wing flap (100) according to claim 5, wherein: The plurality of spars (106) further include a rear spar (114), the rear spar (114) including a rear spar main portion (128) and a rear spar extension portion (130) extending from the rear spar main portion (128); The flap body (164) is formed in part by the rear spar main portion (128); and The torque member (108) is formed in part by the rear spar extension (130).

7. The wing flap (100) of claim 6, wherein at least two of the front spar (110), the intermediate spar (118), and the rear spar (114) converge toward each other adjacent the inboard end of the torque member (108).

8. The wing flap (100) of claim 5, further comprising an extension member (146) coupled to the flap body (164) and located between the front spar extension (122) of the front spar (110) and the intermediate spar extension (134) of the intermediate spar (118), and wherein the torque member (108) is partially formed by the extension member (146).

9. The wing flap (100) of claim 5, further comprising an extension rib (176) extending between the front spar extension portion (122) of the front spar (110) and the intermediate spar extension portion (134) of the intermediate spar (118), and wherein the torque member (108) is partially formed by the extension rib (176).

10. The wing flap (100) according to claim 4, wherein: The plurality of spars (106) include a rear spar (114); The wing flap (100) further includes: an inboard rib (168) extending between the front spar (110) and the rear spar (114) at the inboard end of the flap body (164); and an extension member (146) coupled to the inboard rib (168); The flap body (164) is formed in part by the rear spar (114); and The torque member (108) is formed in part by the extension member (146).

11. The wing flap (100) of claim 1, wherein: The plurality of spars (106) include a rear spar (114), the rear spar (114) including a rear spar main portion (128) and a rear spar extension portion (130) extending from the rear spar main portion (128); The flap body (164) is formed in part by the rear spar main portion (128); and The torque member (108) is formed in part by the rear spar extension (130).

12. The wing flap (100) according to claim 11, wherein: The plurality of spars (106) further include an intermediate spar (118), the intermediate spar (118) including an intermediate spar main portion (132) and an intermediate spar extension portion (134) extending from the intermediate spar main portion (132); The flap body (164) is formed in part by the intermediate spar main portion (132); and The torque member (108) is formed in part by the intermediate spar extension (134).

13. The wing flap (100) of claim 12, further comprising an extension member (146) coupled to the flap body (164) and located between the rear spar extension (130) of the rear spar (114) and the intermediate spar extension (134) of the intermediate spar (118), and wherein the torque member (108) is partially formed by the extension member (146).

14. The wing flap (100) of claim 12, further comprising an extension rib (176) extending between the rear spar extension (130) of the rear spar (114) and the intermediate spar extension (134) of the intermediate spar (118), and wherein the torque member (108) is partially formed by the extension rib (176).

15. The wing flap (100) of claim 11, wherein: The plurality of spars (106) include a front spar (110); The wing flap (100) further includes: an inboard rib (168) extending between the front spar (110) and the rear spar (114) at the inboard end of the flap body (164); and an extension member (146) coupled to the inboard rib (168); The flap body (164) is formed in part by the front spar (110); and The torque member (108) is formed in part by the extension member (146).

16. A wing of an aircraft, the wing comprising: Wing body (258); as well as The wing flap (100) according to any one of claims 1 to 15, wherein the flap body (164) is movably coupled to the wing body (258).

17. A method for forming a wing flap (100) according to any one of claims 1 to 15, the method comprising: The torque member (108) is integrally formed with at least a portion of the flap body (164) to form the wing flap (100), wherein: The flap body (164) is configured to be movably coupled to a wing of an aircraft; and The torque member (108) is configured to be coupled to a flap actuator (260) of the aircraft.

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