Trailing edge flap with a grille internal structure

Abstract

The present invention relates to a trailing edge flap having a grid internal structure. An aircraft flap is constructed of nested layers of composite material in the aircraft flap. The nested layers of composite material include an inner layer, an intermediate layer, and an outer layer. The aircraft flap is constructed such that the inner layer is laid around a central mandrel, the intermediate layer is laid around the inner layer, and the outer layer is laid around the intermediate layer. The inner layer, intermediate layer, and outer layer are co-cured on the mandrel, removed from the mandrel, and then assembled together with an inner layer formed in a folded configuration around a hollow internal volume of the aircraft flap, an intermediate layer formed in a folded configuration on the inner layer, and an outer layer formed in a folded configuration around the intermediate layer.

Description

Technical Field

[0001] The present invention relates to the structure of a trailing edge flap of an aircraft wing. Specifically, the present invention relates to a composite structure of a trailing edge flap of an aircraft wing having a minimal internal support structure and a simplified laminate design. Background Art

[0002] The trailing edge flap of an aircraft wing can be used to increase the lift of the aircraft wing. The trailing edge flap is mounted to the trailing edge of the aircraft wing and selectively extends from or selectively retracts into the trailing edge of the aircraft wing.

[0003] Extending the trailing edge flap from the trailing edge of the aircraft wing increases the surface area on the underside of the aircraft wing. This in turn increases the lift of the aircraft wing. The increased lift of the aircraft wing enables the aircraft to generate the required lift at a lower speed (e.g., takeoff speed).

[0004] Existing trailing edge flaps are constructed using many parts and many fasteners. For example, an existing trailing edge flap can be constructed to have a thin aluminum skin extending across the upper and lower surfaces of the flap and having many internal strengthening elements between the skins. Constructing such a flap with an aluminum skin and many fasteners to secure the skin to many internal strengthening elements is very time-consuming. The aluminum skin, many fasteners, and many internal strengthening elements require a large amount of processing to manufacture the trailing edge flap. In addition, the aluminum skin, many fasteners, and many internal strengthening elements of existing trailing edge flaps also increase the weight of the trailing edge flap. Summary of the Invention

[0005] The trailing edge flap of the present invention and its construction method reduce the number of fasteners and strengthening elements in the trailing edge flap structure, reduce the manufacturing time of the trailing edge flap, thereby saving manufacturing time, reducing manufacturing costs, and reducing the weight of the trailing edge flap.

[0006] The trailing edge flap is composed of nested layers of material, which include an inner layer, a middle layer, and an outer layer. This material is a pre-preg composite material, but other types of materials can also be used.

[0007] The inner layer of the material has a folded configuration in the aircraft flap, which integrally forms the inner layer of the material. The inner layer of the material has a horizontally oriented lower panel, a vertically oriented middle panel extending upward from the lower panel, and a horizontally oriented upper panel extending from the middle panel above the lower panel. The lower panel, the middle panel, and the upper panel extend around a hollow internal volume in the folded configuration of the inner layer of the material.

[0008] The intermediate layer of the material has a folded configuration in the aircraft flap that surrounds the inner layer of the material. The folded configuration of the intermediate layer of the material forms the intermediate layer of the material, which has: a lower panel of the intermediate layer of the material that is horizontally oriented and covers and lies on the lower panel of the inner layer of the material, a middle panel of the intermediate layer of the material that is vertically oriented and extends upward from the lower panel of the intermediate layer of the material and passes through the hollow internal volume in the folded configuration of the inner layer of the material, and an upper panel of the intermediate layer of the material that is horizontally oriented and extends from the middle panel of the intermediate layer of the material and covers and lies on the upper panel of the inner layer of the material.

[0009] The outer layer of the material has a folded configuration in the aircraft flap that surrounds the intermediate layer of the material and the inner layer of the material. The folded configuration of the outer layer of the material integrally forms the outer layer of the material, which has: a lower panel of the outer layer of the material that is horizontally oriented and covers and lies on the lower panel of the intermediate layer of the material, a middle panel of the outer layer of the material that is vertically oriented and extends upward from the lower panel of the outer layer of the material above the middle panel of the intermediate layer of the material, and an upper panel of the outer layer of the material that is horizontally oriented and extends from the middle panel of the outer layer of the material and covers and lies on the upper panel of the intermediate layer of the material.

[0010] The middle panel of the inner layer of the material forms a first spar, such as a rear spar, inside the aircraft flap. The middle panel of the intermediate layer of the material forms a second spar, such as a front spar, inside the aircraft flap. The middle panel of the outer layer of the material forms a part of the outside of the aircraft flap, such as the bullnose or rounded convex surface of the aircraft flap.

[0011] Multiple holes pass through the lower panel of the intermediate layer of the material. There are also multiple holes passing through the upper panel of the intermediate layer of the material. These multiple holes remove composite material from the structure of the intermediate layer of the material and reduce the weight of the aircraft flap.

[0012] An internal support structure is present in the hollow internal volume in the folded configuration of the inner layer of the material. The internal support structure includes a first rib in the hollow internal volume in the folded configuration of the inner layer of the material. The first rib is fixed to the inner layer of the material. The internal support structure also includes a second rib in the hollow internal volume in the folded configuration of the inner layer of the material. The second rib is fixed to the inner layer of the material. The internal support structure further includes an intermediate beam or intermediate spar in the hollow internal volume in the folded configuration of the inner layer of the material. The intermediate spar is located between the first spar and the second spar. The intermediate spar extends between the first rib and the second rib and is fixed to the first rib and the second rib.

[0013] A method of constructing an aircraft flap includes nesting composite material layers, an inner layer, an intermediate layer, and an outer layer in the aircraft flap. The composite material layer is a pre-impregnated composite material layer. Other types of composite materials and other equivalent materials can be used.

[0014] The construction method includes an inner layer of material laid in a folded configuration around a central mandrel, and the method integrally forms the inner layer of material, which has a lower panel, a middle panel extending upward from the lower panel, and an upper panel extending from the middle panel above the mandrel and the lower panel. The lower panel, the middle panel, and the upper panel of the inner layer of material extend around the central mandrel to form the inner layer of material that extends around a hollow internal volume in the folded configuration of the inner layer of material.

[0015] The construction method further includes laying an intermediate layer of material around the inner layer of material in a folded configuration, thereby integrally forming the intermediate layer of material, wherein the lower panel of the intermediate layer of material covers and is laid on the lower panel of the inner layer of material, the middle panel of the intermediate layer of material extends through the hollow internal volume in the folded configuration of the inner layer of material, and the upper panel of the intermediate layer of material covers and is laid on the upper panel of the inner layer of material.

[0016] The construction method still further includes laying an outer layer of material around the intermediate layer of material in a folded configuration to integrally form the outer layer of material, wherein the lower panel of the outer layer of material covers and is laid on the lower panel of the intermediate layer of material, the middle panel of the outer layer of material extends onto the middle panel of the intermediate layer of material, and the upper panel of the outer layer of material covers and is laid on the upper panel of the intermediate layer of material.

[0017] Before the intermediate layer of material is laid around the inner layer of material in a folded configuration, a plurality of holes are formed through the lower panel of the intermediate layer of material and through the upper panel of the intermediate layer of material. The composite material removed from the lower panel of the intermediate layer of material and the upper panel of the intermediate layer of material reduces the weight of the aircraft flap.

[0018] The middle panel of the inner layer of material is formed as a first spar (e.g., the trailing spar of an aircraft flap), and the middle panel of the intermediate layer of material is formed as a second spar (e.g., the leading spar of an aircraft flap), thereby minimizing the internal support structure of the aircraft flap and simplifying the design of the laminate.

[0019] The features, functions, and advantages discussed can be implemented independently in various examples or combined in other examples, and further details thereof can be viewed with reference to the following description and the drawings. Description of the Drawings

[0020] Figure 1 is an illustration of a perspective view of a trailing edge flap of the present invention.

[0021] Figure 2 is Figure 1 an illustration of a perspective view of the inner layer of the trailing edge flap of

[0022] Figure 3 is Figure 1 a perspective view illustration of the middle layer of the trailing edge flap.

[0023] Figure 4 is Figure 1 a perspective view illustration of the outer layer of the trailing edge flap.

[0024] Figure 5 is an end elevation view illustration of the inner layer of the trailing edge flap formed on the central mandrel.

[0025] Figure 6 is an end elevation view illustration of the middle layer of the trailing edge flap formed on the mandrel.

[0026] Figure 7 is an end elevation view illustration of the front mandrel and the rear mandrel attached to the middle layer of the trailing edge flap.

[0027] Figure 8 is an end elevation view illustration of the outer layer of the trailing edge flap formed on the front mandrel, the central mandrel, and the rear mandrel.

[0028] Figure 9 is from Figure 7 and Figure 8 an end elevation view illustration of the inner layer, the middle layer, and the outer layer of the trailing edge flap with the mandrels removed.

[0029] Figure 10 is a perspective view illustration of the internal support structure of the trailing edge flap.

[0030] Figure 11 is an end elevation view illustration of the internal support structure assembled to the inner layer.

[0031] Figure 12 is an end elevation view illustration of the hole machined through the middle layer.

[0032] Figure 13 is an illustration of the middle layer assembled to the inner layer and the internal support structure.

[0033] Figure 14 is an end elevation view illustration of the outer layer assembled to the middle layer, the inner layer, and the internal support structure.

[0034] Figure 15 is a perspective view illustration of the trailing edge flap, where a portion of the outer layer and the middle layer are removed to illustrate the construction of the trailing edge flap.

[0035] Figure 16 is a perspective view illustration of the tail rudder of the present invention.

[0036] Figure 17A perspective view illustration of a component of the tail rudder of an aircraft assembled with an internal support structure, an inner layer, an intermediate layer, and an outer layer. Detailed Description

[0037] Figure 1 A perspective view illustration of the trailing edge flap 12 of the present invention. The trailing edge flap 12 is composed of nested layers of composite materials, which include an inner layer 14, an intermediate layer 16, and an outer layer 18. In the present invention, the composite material of each of the inner layer 14, the intermediate layer 16, and the outer layer 18 is a pre-impregnated composite material. However, other types of composite materials can be used to construct the layers to be described, and materials other than composite materials can also be used.

[0038] Figure 2 is from Figure 1 A perspective view illustration of the inner layer 14 of the material removed from the structure of the trailing edge flap 12. The inner layer 14 of the material can be a single or monolithic composite material (such as a pre-impregnated composite material), or multiple layers of composite materials. The inner layer 14 of the material has a generally rectangular configuration, with its longitudinal length extending between the inner edge 22 and the opposite outer edge 24 of the inner layer 14 of the material, and its transverse width extending between the lower edge 26 and the opposite upper edge 28 of the inner layer 14 of the material. The longitudinal length of the inner layer 14 of the material will extend along the longitudinal length of the trailing edge flap 12 to be constructed. Figure 2 The relative length and width dimensions of the inner layer 14 of the material shown in are only examples. The relative length and width dimensions of the inner layer 14 will vary depending on the length and width dimensions of the trailing edge flap being constructed. As shown in Figure 2 shown, the inner layer 14 of the material forms a folded configuration. The "folded configuration" means that a part of the inner layer 14 of the material adjacent to the upper edge 28 is overlapped or positioned on a part of the inner layer 14 of the material near the lower edge 26. Figure 2 The folded configuration of the inner layer 14 of the material shown in is achieved by folding the inner layer 14 of the material around a central mandrel.

[0039] Figure 5 A front view illustration of the end of the inner layer 14 of the material folded around the central mandrel 32. The central mandrel 32 has a bottom surface 34 and an opposite top surface 36, a first side surface 38, and an opposite second side surface 42. The length dimension of the central mandrel 32 depends on the length dimension of the trailing edge flap being constructed. As shown in Figure 5As shown, the inner layer 14 of the material is folded over the central mandrel 32 to form a folded configuration of the inner layer 14. The folded configuration of the inner layer 14 of the material forms an inner layer having: a lower panel 44 on the bottom surface 34 of the central mandrel 32, a middle panel 46 on the first side surface 38 of the central mandrel, and an upper panel 48 on the top surface 36 of the central mandrel 32. Folding the inner layer 14 of the material over the central mandrel 32 integrally forms the inner layer 14 of the material, which has: a horizontally oriented lower panel 44, a vertically oriented middle panel 46 extending upward from the lower panel 44, and a horizontally oriented upper panel 48 extending from the middle panel 46 above the lower panel 44. The lower panel 44, middle panel 46, and upper panel 48 of the inner layer 14 of the material extend around a hollow interior volume 52 in the folded configuration of the inner layer 14 of the material.

[0040] Figure 3 is removed from Figure 1 A perspective view illustration of the intermediate layer 16 of the material removed from the structure of the trailing edge flap 12. Like the inner layer 14 of the material, the intermediate layer 16 of the material can be a single layer or a single-piece composite material (e.g., a pre-impregnated composite material), or a multi-piece composite material. Figure 3 The illustration of the intermediate layer 16 of the material in [reference] has a generally rectangular configuration, with its longitudinal length extending between the inner edge 62 and the opposite outer edge 64 of the intermediate layer 16 of the material, and its transverse width extending between the lower edge 66 and the opposite upper edge 68 of the inner layer 16 of the material. The rectangular configuration of the intermediate layer 16 of the material is just an example of a feasible configuration. The configuration of the intermediate layer 16 of the material will vary based on the configuration of the trailing edge flap to be constructed. Like the inner layer 14 of the material, the longitudinal length of the intermediate layer 16 of the material will extend along the longitudinal length of the trailing edge flap 12 to be constructed. Figure 3 The relative length and width dimensions of the intermediate layer 16 of the material shown are only examples. The relative length and width dimensions of the intermediate layer 16 of the material will vary based on the length and width dimensions of the trailing edge flap to be constructed. As Figure 3 shown, the intermediate layer 16 of the material is formed in a folded configuration. "Folded configuration" means that a portion of the intermediate layer 16 of the material adjacent to the upper edge 68 is overlapped or positioned on a portion of the intermediate layer 16 of the material adjacent to the lower edge 66. Figure 3 The folded configuration of the intermediate layer 16 of the material shown is achieved by folding the intermediate layer 16 of the material over the inner layer 14 of the material on the central mandrel 32.

[0041] Figure 6It is an illustration of a front view of the end of the intermediate layer 16 of the material, which is folded over the inner layer 14 of the material. The inner layer 14 of the material has previously been folded over the central mandrel 32. Before folding the intermediate layer 16 over the inner layer 14, a release agent is applied to the lower panel 44 of the inner layer, the middle panel 46 of the inner layer, and the upper panel 48 of the inner layer. Then the intermediate layer 16 is folded over the inner layer 14 to form a folded configuration of the intermediate layer 16. The folded configuration of the intermediate layer 16 of the material forms an intermediate layer having a lower panel 72 that covers and lies on the lower panel 44 of the inner layer 14, a middle panel 74 that covers and lies on the second side surface 42 of the central mandrel 32, and an upper panel 76 that covers and lies on the upper panel 48 of the inner layer 14. The intermediate layer 16 of the material is formed on the inner layer 14 of the material that has been previously folded over the central mandrel 32, which integrally forms the intermediate layer 16 of the material, wherein the lower panel 72 of the intermediate layer is horizontally oriented, the middle panel 74 of the intermediate layer is vertically oriented and extends upward from the lower panel 72 of the intermediate layer, and the upper panel 76 is horizontally oriented and extends from the middle panel 74 to the lower panel 72 of the intermediate layer and the upper panel 48 of the inner layer 14. The lower panel 72, the middle panel 74, and the upper panel 76 of the intermediate layer 16 of the material extend around the inner layer 14 of the material and the hollow interior volume 52 in the folded configuration of the inner layer 14 of the material.

[0042] As Figure 3 shown, there are a plurality of holes 78 passing through the lower panel 72 of the intermediate layer 16. Each of the plurality of holes 78 has a polygonal configuration. There are also a plurality of holes 82 formed through the upper panel 76 of the intermediate layer 16. Each of these plurality of holes 82 also has a polygonal configuration. The plurality of holes 78, 82 are formed in the intermediate layer 16 of the material in a later manufacturing step of the intermediate layer of the material. The plurality of holes 78, 82 remove composite material from the structure of the intermediate layer 16 of the material, thereby reducing the weight of the intermediate layer 16 of the material and the weight of the trailing edge flap 12 constructed from the intermediate layer 16 of the material.

[0043] Figure 4 is an illustration of a perspective view of the outer layer 18 of the material removed from the structure of the Figure 1 trailing edge flap 12. Like the inner layer 14 of the material and the intermediate layer 16 of the material, the outer layer 18 of the material can be a single-layer or single-piece composite material (e.g., a pre-impregnated composite material), or a multi-layer composite material. As Figure 4 shown, the outer layer 18 of the material has a generally rectangular configuration, with its longitudinal length extending between the inner edge 84 and the opposite outer edge 86 of the outer layer 18 of the material, and its transverse width extending between the lower edge 88 and the opposite upper edge 92 of the outer layer 18 of the material. The longitudinal length of the outer layer 18 of the material will extend along the longitudinal length of the constructed trailing edge flap. Figure 4The relative length and width dimensions of the outer layer 18 of the material shown are merely examples. The relative length and width dimensions of the outer layer 18 of the material will vary depending on the length and width dimensions of the trailing edge flap being constructed. As Figure 4 shown, the outer layer 18 of the material is formed in a folded configuration. The "folded configuration" means that a portion of the outer layer 18 of the material adjacent to the upper edge 92 is overlapped or positioned on a portion of the outer layer 18 of the material adjacent to the lower edge 88. Figure 4 The folded configuration of the outer layer 18 of the material shown is achieved by folding the outer layer 18 of the material over the intermediate layer 16 of the material, over the inner layer 14 of the material, and over the central mandrel 32.

[0044] Before the outer layer 18 of the material is folded over the intermediate layer 16 of the material in its folded configuration, the inner layer 14 and the central mandrel 32, the front mandrel 94, and the rear mandrel 96 are added to the central mandrel 32.

[0045] As Figure 7 shown, the front mandrel 94 has a flat rear surface 98 that is positioned against the middle panel 74 of the intermediate layer. The front mandrel 94 also has a front surface 102 that projects outwardly from the flat rear surface 98. The front surface 102 has a generally semi-circular configuration in cross-section. The length dimension of the front mandrel 94 depends on the length dimension of the trailing edge flap being constructed.

[0046] The rear mandrel 96 has a front surface 104 that is positioned to abut the middle panel 74 of the intermediate layer 16. The rear mandrel 96 has a rear surface 106 that projects rearwardly from the front surface 104. The rear surface 106 gives the rear mandrel 96 a triangular cross-sectional configuration. The length dimension of the rear mandrel 96 depends on the length dimension of the trailing edge flap being constructed.

[0047] Figure 8 is an end view illustration of the outer layer 18 of the material folded over the front mandrel 94, the intermediate layer 16 folded over the inner layer 14 and the central mandrel 32, and the end of the rear mandrel 96. Before the outer layer 18 of the material is folded over the front mandrel 94, the intermediate layer 16, and the rear mandrel 96, a release agent, such as a release film, is applied to the front surface 102 of the front mandrel, the lower panel 72 of the intermediate layer, the upper panel 76 of the intermediate layer, and the rear surface 106 of the rear mandrel. As Figure 8As shown, the outer layer 18 of the material is folded over the front mandrel 94, the lower panel 72 of the intermediate layer, the upper panel 76 of the intermediate layer, and the rear mandrel 96 to form a folded configuration of the outer layer 18 of the material. The folded configuration of the outer layer 18 forms an outer layer having a lower panel 112 that covers and lies on the rear surface 106 of the lower panel 72 of the intermediate layer 16 and the rear mandrel 96, a middle panel 114 that lies on the front surface 102 of the front mandrel 94, and an upper panel 116 that covers and lies on the upper panel 76 of the intermediate layer 16 of the material and the rear surface 106 of the rear mandrel 96. Folding the outer layer 18 of the material over the front mandrel 94, the intermediate layer 16 of the material, and the rear mandrel 96 integrally forms the outer layer 18 of the material, which has a horizontally oriented lower panel 112, a vertically oriented middle panel 114 that extends upward from the lower panel 112, and a horizontally oriented upper panel 116 that extends from the middle panel 114 above the lower panel 112. The lower panel 112, the middle panel 114, and the upper panel 116 of the outer layer 18 of the material extend around the hollow interior volume 52 in the folded configuration of the inner layer 14 of the material. Then, as Figure 8 shown, the inner layer 14 of the material, the intermediate layer 16 of the material, and the outer layer 18 of the material assembled on the central mandrel 32, the front mandrel 94, and the rear mandrel 96 are autoclave processed. The autoclave processing heats and pressurizes the inner layer 14 of the material, the intermediate layer 16 of the material, and the outer layer 18 of the material to cure the inner layer 14 of the material, the intermediate layer 16 of the material, and the outer layer 18 of the material. After the autoclave processing, the inner layer 14 of the material, the intermediate layer 16 of the material, and the outer layer 18 of the material are removed from the central mandrel 32, the front mandrel 94, and the rear mandrel 96. Figure 9 is an end - elevation view illustration of the inner layer 14 of the material, the intermediate layer 16 of the material, and the outer layer 18 of the material after being removed from the mandrel.

[0048] Figure 10 is a perspective - view illustration of the internal support structure 118 of the trailing - edge flap 12. The internal support structure 118 includes a first rib 122. The first rib 122 is made of metal or other equivalent material. The first rib 122 has an outer - surface configuration or an outer - peripheral - surface configuration that conforms to Figure 9 the inner - surface configuration of the inner layer 14 of the material as shown. The internal support structure 118 also includes a second rib 124. The second rib 124 has an external configuration or an outer - peripheral - surface configuration that is substantially the same as that of the first rib 122. The second rib 124 is also made of metal or other equivalent material. The outer - surface configuration of the second rib 124 also conforms to the configuration of the inner surface of the inner layer 14 of the material as shown in Figure 9 shown. The internal support structure 118 further includes an intermediate beam or spar 126. The intermediate spar 126 is made of a composite material or other equivalent material. As Figure 10As shown, the intermediate spar 126 extends between the first rib 122 and the second rib 124 and is fixed to the first rib 122 and the second rib 124.

[0049] When constructing the trailing edge flap 12, the internal support structure 118 is positioned within the hollow internal volume 52 of the inner layer 14 of the material. Figure 11 FIG. is a front view of the end of the internal support structure 118 inserted into the hollow internal volume 52 of the inner layer 14 of the material. The first rib 122 is fixed to the inner layer 14 of the material by fasteners or other equivalent means. The second rib 124 is fixed to the inner layer 14 of the material by fasteners or other equivalent means.

[0050] Then a plurality of holes 78 are formed through the lower panel 72 of the intermediate layer 16 of the material. Figure 3 The plurality of holes 82 shown are also formed through the upper panel 76 of the intermediate layer 16 of the material. As Figure 3 shown, the plurality of holes 78, 82 have a polygonal configuration. This positions the edges of the plurality of holes 78, 82 parallel to the fibers of the composite material of the intermediate layer 16 of the material. The plurality of holes 78, 82 remove the composite material from the structure of the intermediate layer 16 of the material and reduce the weight of the intermediate layer 16 of the material and the weight of the trailing edge flap 12. Figure 12 FIG. is a front cross-sectional view of the intermediate layer 16 of the material having a plurality of holes 78 through the lower panel 72 of the intermediate layer 16 of the material and a plurality of holes 82 through the upper panel 76 of the intermediate layer 16 of the material.

[0051] Figure 13 FIG. is a front view of the end of the intermediate layer 16 of the material assembled to the inner layer 14 of the material, which inner layer of the material has been previously fixed to the internal support structure 118 located within the hollow internal volume 52 of the inner layer 14 of the material. As Figure 13 shown, the intermediate layer 16 of the material is assembled to the inner layer 14 of the material with a thin film adhesive layer between the plurality of mating surfaces of the intermediate layer 16 of the material and the inner layer 14 of the material. After autoclave treatment, Figure 9 the inner layer 14 of the material, the intermediate layer 16 of the material, and the outer layer 18 of the material shown have elasticity. This enables the inner layer 14 of the material, the intermediate layer 16 of the material, and the outer layer 18 of the material to be assembled to each other.

[0052] In the case where the intermediate layer 16 of the material is assembled to the inner layer 14 of the material in its folded configuration, the outer layer 18 of the material is assembled to the intermediate layer 16 of the material in its folded configuration. Before assembling the outer layer 18 of the material to the intermediate layer 16 of the material, an adhesive film is applied between the plurality of mating surfaces of the outer layer 18 of the material and the intermediate layer 16 of the material. Figure 14 FIG. is an end view of the outer layer 18 of the material assembled to the intermediate layer 16 of the material. In asFigure 14 In the case where the outer layer 18 of the material is assembled on the middle layer 16 of the material as shown, the wedge 132 of the composite material is positioned between the lower panel 112 of the outer layer 18 of the material and the upper panel 116 of the outer layer 18 of the material at the lower edge 88 and the upper edge 92 of the outer layer 18 of the material. The positioning of the wedge 132 is as Figure 14 shown.

[0053] Then Figure 14 the assembled internal support structure 118, the inner layer 14 of the material, the middle layer 16 of the material, the outer layer 18 of the material, and the wedge 132 shown in Figure 15 are vacuum encapsulated and hot pressed again. This forms a secondary cured bond between the inner layer 14 of the material, the middle layer 16 of the material, the outer layer 18 of the material, and the wedge 132. After the second autoclave treatment, the construction of the trailing edge flap 12 is completed.

[0054] Although the present invention describes the structure of the trailing edge flap 12, the concept of the present invention can also be used to manufacture other structures of an aircraft. For example, the concept of the present invention can be used to manufacture the vertical tail and rudder assembly of an aircraft. Figure 16 is a schematic diagram of the components that enter the construction of the tail rudder 134. Figure 16 is a schematic diagram of the inner layer 136 of the material, the middle layer 138 of the material, and the outer layer 142 of the material, which are respectively made of a composite material (such as a pre-impregnated composite material). The tail rudder 134 also has an internal support structure in the form of a plurality of ribs 144. The ribs 144 are made of metal or other equivalent materials. The inner layer 136 of the material, the middle layer 138 of the material, the outer layer 142 of the material, and the ribs 144 are assembled together in the same manner as the construction of the trailing edge flap 12 to form the tail rudder 134.

[0055] In addition, the present invention includes embodiments according to the following clauses:

[0056] Clause 1. An aircraft flap 12, comprising:

[0057] Nested layers of composite material in the aircraft flap 12, including an inner layer 14, a middle layer 16, and an outer layer 18;

[0058] The inner layer 14 has a folded configuration in the aircraft flap 12, thereby integrally forming a lower panel 44, a middle panel 46 extending upward from the lower panel, and an upper panel 48 extending from the middle panel on the lower panel. The lower panel 44, the middle panel 46, and the upper panel 48 extend around a hollow internal volume 52 in the folded configuration of the inner layer 14;

[0059] The intermediate layer 16 has a folded configuration in the aircraft flap 12, thereby integrally forming a lower panel 72 of the intermediate layer 16 covering the lower panel 44 of the inner layer 14, a middle panel 74 of the intermediate layer 16 extending through the hollow internal volume 52 in the folded configuration of the inner layer 14, and an upper panel 76 of the intermediate layer 16 covering the upper panel 48 of the inner layer 14, and

[0060] The outer layer 18 has a folded configuration in the aircraft flap 12, thereby integrally forming a lower panel 112 of the outer layer 18 covering the lower panel 72 of the intermediate layer 16, a middle panel 114 of the outer layer 18 extending on the middle panel 74 of the intermediate layer 16, and an upper panel 116 of the outer layer 18 covering the upper panel 76 of the intermediate layer 16.

[0061] Clause 2. The aircraft flap 12 according to Clause 1, further comprising:

[0062] The middle panel 46 of the inner layer 14 forms the first spar of the aircraft flap 12.

[0063] Clause 3. The aircraft flap 12 according to Clause 2, further comprising:

[0064] The middle panel 74 of the intermediate layer 16 forms the second spar of the aircraft flap 12.

[0065] Clause 4. The aircraft flap 12 according to Clause 3, further comprising:

[0066] The middle panel 114 of the outer layer 18 forms the circular convex surface of the aircraft flap 12.

[0067] Clause 5. The aircraft flap 12 according to any one of Clauses 1-5, further comprising:

[0068] A plurality of holes 78 passing through the lower panel 72 of the intermediate layer 16; and

[0069] A plurality of holes 82 passing through the upper panel 76 of the intermediate layer 16.

[0070] Clause 6. The aircraft flap 12 according to Clause 5, further comprising:

[0071] Each of the plurality of holes 78, 82 has a polygonal configuration.

[0072] Clause 7. The aircraft flap 12 according to any one of Clauses 1 - 6 further comprises:

[0073] An internal support structure 118 within a hollow internal volume 52 in the folded configuration of the inner layer 14, the internal support structure 118 including a first rib 122 fixed to the lower panel 44 and the upper panel 48 of the inner layer 14, a second rib 124 fixed to the lower panel 44 and the upper panel 48 of the inner layer 14, and an intermediate spar 126 fixed to the first rib 122 and the second rib 124.

[0074] Clause 8. An aircraft flap 12 comprising:

[0075] An inner layer 14 of material having a folded configuration that forms the inner layer 14 of material, which has: a horizontally oriented lower panel 44, a vertically oriented middle panel 46 extending upward from the lower panel 44, and a horizontally oriented upper panel 48 extending from the middle panel 46 on the lower panel 44, the lower panel 44, the middle panel 46, and the upper panel 48 extending around a hollow internal volume 52 in the folded configuration of the inner layer 14 of material;

[0076] An intermediate layer 16 of material having a folded configuration around the inner layer 14 of material, the folded configuration forming the intermediate layer 16 of material having: a horizontally oriented lower panel 72 of the intermediate layer 16 of material laid on the lower panel 44 of the inner layer 14 of material, a vertically oriented middle panel 74 of the intermediate layer 16 of material extending upward from the lower panel 72 of the intermediate layer 16 of material and passing through the hollow internal volume 52 in the folded configuration of the inner layer 14 of material, and a horizontally oriented upper panel 76 of the intermediate layer 16 of material extending from the middle panel 74 of the intermediate layer 16 of material and laid on the upper panel 48 of the inner layer 14 of material; and

[0077] An outer layer 18 of material having a folded configuration around the intermediate layer 16 of material and the inner layer 14 of material, the folded configuration of the outer layer 18 of material having: a horizontally oriented lower panel 112 laid on the lower panel 72 of the intermediate layer 16 of material, a vertically oriented middle panel 114 of the outer layer 18 of material extending upward from the lower panel 112 of the outer layer 18 of material above the middle panel 74 of the intermediate layer 16 of material, and a horizontally oriented upper panel 116 of the outer layer 18 of material extending from the middle panel 114 of the outer layer 18 of material and laid on the upper panel 76 of the intermediate layer 16 of material.

[0078] Clause 9. The aircraft flap 12 according to Clause 8 further comprises:

[0079] The middle panel 46 of the inner layer 14 of material forms the first spar of the aircraft flap.

[0080] Clause 10. The aircraft flap 12 according to Clause 9 further comprises:

[0081] The middle panel 74 of the intermediate layer 16 of the material forms the second spar of the aircraft flap.

[0082] Clause 11. The aircraft flap 12 according to Clause 10 further comprises:

[0083] The middle panel 114 of the outer layer 18 of the material forms the circular convex surface of the aircraft flap 12.

[0084] Clause 12. The aircraft flap 12 according to any one of Clauses 8 - 11 further comprises:

[0085] The lower panel 44 of the inner layer 14 of the material, the middle panel 46 of the inner layer 14 of the material, and the upper panel 48 of the inner layer 14 of the material are integrally formed.

[0086] Clause 13. The aircraft flap 12 according to Clause 12 further comprises:

[0087] The lower panel 72 of the intermediate layer 16 of the material, the middle panel 74 of the intermediate layer 16 of the material, and the upper panel 76 of the intermediate layer 16 of the material are integrally formed.

[0088] Clause 14. The aircraft flap 12 according to Clause 13 further comprises:

[0089] The lower panel 112 of the outer layer 18 of the material, the middle panel 114 of the outer layer 18 of the material, and the upper panel 116 of the outer layer 18 of the material are integrally formed.

[0090] Clause 15. The aircraft flap 12 according to any one of Clauses 8 - 14 further comprises:

[0091] The inner layer 14 of the material is a composite material;

[0092] The intermediate layer 16 of the material is a composite material; and

[0093] The outer layer 18 of the material is a composite material.

[0094] Clause 16. The aircraft flap 12 according to any one of Clauses 8 - 15 further comprises:

[0095] A plurality of holes 78 passing through the lower panel 72 of the intermediate layer 16 of the material; and

[0096] A plurality of holes 82 passing through the upper panel 76 of the intermediate layer 16 of the material.

[0097] Clause 17. The aircraft flap 12 according to any one of Clauses 8-16 further comprises:

[0098] A first rib 122 in a hollow internal volume 52 in a folded configuration of an inner layer 14 of the material, the first rib 122 being fixed to the inner layer 14 of the material;

[0099] A second rib 124 in an empty internal volume 52 in a folded configuration of the inner layer 14 of the material, the second rib 122 being fixed to the inner layer 14 of the material; and

[0100] An intermediate spar 126 in an empty internal volume 52 in a folded configuration of the inner layer 14 of the material, the intermediate spar 126 being fixed to the first rib 122 and the second rib 124.

[0101] Clause 18. A method of constructing an aircraft flap 12, the method comprising:

[0102] Nesting material layers in the aircraft flap 12, the material layers including an inner layer 14, an intermediate layer 16, and an outer layer 18;

[0103] Laying the inner layer 14 in a folded configuration around a central mandrel 32 so as to integrally form the inner layer 14 having: a lower panel 44, a middle panel 46 extending upward from the lower panel 44, and an upper panel 48 extending from the middle panel 46 above the lower panel 44, the lower panel 44, the middle panel 46, and the upper panel 48 extending around a hollow internal volume 52 in the folded configuration of the inner layer 14;

[0104] Laying the intermediate layer 16 in a folded configuration around the inner layer 14 so as to integrally form the intermediate layer 16 having: a lower panel 72 of the intermediate layer 16 covering the lower panel 44 of the inner layer 14, a middle panel 74 of the intermediate layer 16 extending through the hollow internal volume 52 in the folded configuration of the inner layer 14, and an upper panel 76 of the intermediate layer 16 covering the upper panel 46 of the inner layer 14; and

[0105] Laying the outer layer 18 in a folded configuration around the intermediate layer 16 so as to integrally form the outer layer 18 having: a lower panel 112 of the outer layer 18 covering the lower panel 72 of the intermediate layer 16, a middle panel 114 of the outer layer 18 extending onto the middle panel 74 of the intermediate layer 16, and an upper panel 116 of the outer layer 18 covering the upper panel 76 of the intermediate layer 16.

[0106] Clause 19. The method according to Clause 18 further comprises:

[0107] Forming a plurality of holes 78 through the lower panel 72 of the intermediate layer 16, and

[0108] Form a plurality of holes 82 through the upper panel 76 of the intermediate layer 16.

[0109] Clause 20. The method according to any one of Clauses 18 - 19 further comprises:

[0110] Form a middle panel 46 of the inner layer 14 that serves as the first spar of the aircraft flap 12, and

[0111] Form a middle panel 74 of the intermediate layer 16 that serves as the second spar of the aircraft flap 12.

[0112] Since various modifications can be made to the construction of the trailing edge flap and the method of constructing the same described and illustrated herein without departing from the scope of the present invention, all of the subject matter included in the above description or shown in the accompanying drawings should be construed as illustrative rather than restrictive. Accordingly, the breadth and scope of the present invention should not be limited by any of the above examples, but should be defined only in accordance with the appended claims and their equivalents.

Claims

1. An aircraft flap (12), comprising: a nested layer of composite material in the aircraft flap (12), the nested layer including an inner layer (14), an intermediate layer (16), and an outer layer (18); the inner layer (14) has a folded configuration in the aircraft flap (12) such that it integrally forms a lower panel, a middle panel extending upward from the lower panel, and an upper panel extending from the middle panel on the lower panel, the lower panel, the middle panel, and the upper panel extending around a hollow internal volume (52) in the folded configuration of the inner layer (14); the intermediate layer (16) has a folded configuration in the aircraft flap (12) such that it integrally forms a lower panel of the intermediate layer (16) covering the lower panel of the inner layer (14), a middle panel of the intermediate layer (16) extending through the hollow internal volume (52) in the folded configuration of the inner layer (14), and an upper panel of the intermediate layer (16) covering the upper panel of the inner layer (14); and the outer layer (18) has a folded configuration in the aircraft flap (12) such that it integrally forms a lower panel of the outer layer (18) covering the lower panel of the intermediate layer (16), a middle panel of the outer layer (18) extending on the middle panel of the intermediate layer (16), and an upper panel of the outer layer (18) covering the upper panel of the intermediate layer (16); and an internal support structure (118) in the hollow internal volume (52) in the folded configuration of the inner layer (14), the internal support structure (118) including a first rib (122) fixed to the lower panel and the upper panel of the inner layer (14), a second rib (124) fixed to the lower panel and the upper panel of the inner layer (14), and an intermediate spar (126) fixed to the first rib (122) and the second rib (124).

2. The aircraft flap (12) according to claim 1, further comprising: the middle panel of the inner layer (14) forms a first spar of the aircraft flap (12).

3. The aircraft flap (12) according to claim 2, further comprising: the middle panel of the intermediate layer (16) forms a second spar of the aircraft flap (12).

4. The aircraft flap (12) according to claim 3, further comprising: the middle panel of the outer layer (18) forms a circular convex surface of the aircraft flap (12).

5. The aircraft flap (12) according to any one of claims 1 - 4, further comprising: a plurality of holes (78) passing through the lower panel of the intermediate layer (16); and a plurality of holes (82) passing through the upper panel of the intermediate layer (16).

6. The aircraft flap (12) according to claim 5, further comprising: each of the plurality of holes (78, 82) has a polygonal configuration.

7. The aircraft flap (12) according to claim 3, wherein the first spar is a rear spar and the second spar is a front spar.

8. The aircraft flap (12) according to claim 4, wherein the lower panel and the upper panel of the outer layer respectively form the lower surface and the upper surface of the aircraft flap.

9. The aircraft flap (12) according to any one of claims 1 - 4, wherein: the first rib has an outer peripheral surface configuration that conforms to the inner surface of the inner layer of the material; and the second rib has an outer peripheral configuration that conforms to the inner surface of the inner layer of the material.

10. A method of constructing an aircraft flap (12), the method comprising: nesting material layers in the aircraft flap (12), the material layers including an inner layer (14), an intermediate layer (16), and an outer layer (18); laying the inner layer (14) in a folded configuration around a central mandrel (32) so as to integrally form the inner layer (14), the inner layer having a lower panel, a middle panel extending upward from the lower panel, and an upper panel extending from the middle panel on the lower panel, the lower panel, the middle panel, and the upper panel extending around a hollow inner volume (52) in the folded configuration of the inner layer (14); laying the intermediate layer (16) in a folded configuration around the inner layer (14) so as to integrally form the intermediate layer (16), the intermediate layer having a lower panel of the intermediate layer (16) covering the lower panel of the inner layer (14), a middle panel of the intermediate layer (16) extending through the hollow inner volume (52) in the folded configuration of the inner layer (14), and an upper panel of the intermediate layer (16) covering the upper panel of the inner layer (14); and laying the outer layer (18) in a folded configuration around the intermediate layer (16) so as to integrally form the outer layer (18), the outer layer (18) having a lower panel of the outer layer (18) covering the lower panel of the intermediate layer (16), a middle panel of the outer layer (18) extending on the middle panel of the intermediate layer (16), and an upper panel of the outer layer (18) covering the upper panel of the intermediate layer (16); positioning an internal support structure (118) in the hollow inner volume (52) in the folded configuration of the inner layer (14), the internal support structure (118) including a first rib (122), a second rib (124), and an intermediate spar (126) fixed to the first rib (122) and the second rib (124); fixing the first rib (122) to the lower panel and the upper panel of the inner layer (14); fixing the second rib (124) to the lower panel and the upper panel of the inner layer (14).

11. The method according to claim 10, further comprising: forming a plurality of holes (78) through the lower panel of the intermediate layer (16); and forming a plurality of holes (82) through the upper panel of the intermediate layer (16).

12. The method according to claim 10 or 11, further comprising: Forming a middle panel of the inner layer (14) that serves as the first spar of the aircraft flap (12); And Forming a middle panel of the intermediate layer (16) that serves as the second spar of the aircraft flap (12).

13. The method according to claim 12, wherein: The first spar is a rear spar; The second spar is a front spar; and The lower panel, the middle panel, and the upper panel of the outer layer form the outer surface of the aircraft flap.

14. An aircraft flap, comprising: An inner layer of material having a folded configuration within the aircraft flap, the folded configuration forming the inner layer of material, the inner layer having: a horizontally oriented lower panel, a vertically oriented middle panel extending upward from the lower panel, and a horizontally oriented upper panel extending from the middle panel on the lower panel, the lower panel, the middle panel, and the upper panel extending around a hollow inner volume within the folded configuration of the inner layer of material, the middle panel of the inner layer forming a first spar; An intermediate layer of material having a folded configuration around the inner layer of material, the folded configuration of the intermediate layer of material having: a lower panel of the intermediate layer of material that is horizontally oriented and laid on the lower panel of the inner layer of material, a middle panel of the intermediate layer of material that is vertically oriented and extends upward from the lower panel of the intermediate layer of material and passes through the hollow inner volume within the folded configuration of the inner layer of material, and an upper panel of the intermediate layer of material that is horizontally oriented and extends from the middle panel of the intermediate layer of material and is laid on the upper panel of the inner layer of material, the middle panel of the intermediate layer forming a second spar; An outer layer of material having a folded configuration around the intermediate layer of material and the inner layer of material, the folded configuration of the outer layer of material having: a lower panel that is horizontally oriented and laid on the lower panel of the intermediate layer of material, a middle panel of the outer layer of material that is vertically oriented and extends upward from the lower panel of the outer layer of material above the middle panel of the intermediate layer of material, and an upper panel of the outer layer of material that is horizontally oriented and extends from the middle panel of the outer layer of material and is laid on the upper panel of the intermediate layer of material, the middle panel of the outer layer forming the outer surface of the aircraft flap; An internal support structure within the hollow inner volume in the folded configuration of the inner layer of material, the internal support structure including: A first rib fixed to the inner layer of material; A second rib fixed to the inner layer of material; and An intermediate spar positioned between the first spar and the second spar, the intermediate spar being fixed to the first rib and the second rib and extending between the first rib and the second rib.

15. The aircraft flap according to claim 14, wherein the first spar is a rear spar and the second spar is a front spar.

16. The aircraft flap according to claim 15, wherein the outer surface forming the middle panel of the outer layer is a circular convex surface.

17. The aircraft flap according to claim 16, wherein the lower panel and the upper panel of the outer layer respectively form the lower surface and the upper surface of the aircraft flap.

18. The aircraft flap according to claim 14, wherein: the first rib has a peripheral surface configuration that conforms to the inner surface of the inner layer of the material; and the second rib has a peripheral configuration that conforms to the inner surface of the inner layer of the material.

19. The aircraft flap according to claim 14, wherein the lower panel, the middle panel, and the upper panel of the inner layer are integrally formed.

20. The aircraft flap according to claim 19, wherein the lower panel, the middle panel, and the upper panel of the intermediate layer are integrally formed.

21. The aircraft flap according to claim 20, wherein the lower panel, the middle panel, and the upper panel of the outer layer are integrally formed.

22. The aircraft flap according to claim 14, wherein: the inner layer of the material is a composite material; the intermediate layer of the material is a composite material; and the outer layer of the material is a composite material.

23. The aircraft flap according to claim 22, further comprising: a plurality of holes passing through the lower panel of the intermediate layer of the material, the plurality of holes passing through the lower panel of the intermediate layer having a polygonal configuration that positions the edges of the plurality of holes passing through the lower panel of the intermediate layer parallel to the fibers of the composite material of the intermediate layer; and a plurality of holes passing through the upper panel of the intermediate layer of the material, the plurality of holes passing through the upper panel of the intermediate layer having a polygonal configuration that positions the edges of the plurality of holes passing through the upper panel of the intermediate layer parallel to the fibers of the composite material of the intermediate layer.

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