Leading edge slat for an aircraft, wing of an aircraft and method for an aircraft wing

Abstract

A leading edge slat for an aircraft, a wing of an aircraft, and a method for an aircraft wing are disclosed. The disclosed exemplary leading edge slat for an aircraft includes a single-piece front skin and a box spar, the single-piece front skin defining an upper outer surface and a lower outer surface of the leading edge slat, wherein the single-piece front skin extends between a front end and a rear end of the leading edge slat, and the box spar is coupled to an inner surface of the single-piece front skin. The box spar includes a lateral wall extending away from the inner surface of the single-piece front skin. The lateral wall defines at least one compartment of the box spar.

Description

Technical Field

[0001] The present disclosure relates generally to aircraft and, more particularly, to continuous skin leading edge slats. Background Art

[0002] Aircraft employ high-lift devices, sometimes called slats, along the leading and trailing edges of the wings. For example, high-lift devices along the leading edge of the wing are called leading edge slats, and high-lift devices along the trailing edge of the wing are called trailing edge flaps. The high-lift devices are actuated to extend outward from the wing, thereby changing the aerodynamic lift of the wing during takeoff and landing. Each high-lift device is actuated by one or more drive mechanisms that are coupled to ribs or support beams in the wing.

[0003] Some known leading edge slats use an external skin positioned and mounted by their internal structure. Specifically, the nose skin of the leading edge slat is aligned with a wedge via a spar, which is mechanically fastened and defines a joint therebetween. However, this joint is typically located on the aerodynamic surface of the slat, thereby causing a geometric discontinuity (e.g., a seam) on the aerodynamic surface. As a result, the drag coefficient of the slat may be relatively high, resulting in higher fuel consumption and, therefore, associated costs. Summary of the invention

[0004] An exemplary slat includes a one-piece front skin and a box spar, the one-piece front skin defining an upper outer surface and a lower outer surface of the slat, wherein the one-piece front skin extends between a front end and a rear end of the slat, and the box spar is coupled to an inner surface of the one-piece front skin. The box spar includes a lateral wall extending away from the inner surface of the one-piece front skin. The lateral wall defines at least one compartment of the box spar.

[0005] An exemplary wing of an aircraft includes a fixed wing portion defining an aerodynamic surface of the aircraft, and a leading edge slat movably coupled to the fixed wing portion. The leading edge slat includes a single-piece front skin defining an upper outer surface and a lower outer surface of the leading edge slat, wherein the single-piece front skin extends between a forward end and a rearward end of the leading edge slat, and a box spar coupled to an inner surface of the single-piece front skin, wherein the box spar includes lateral walls extending away from the inner surface and defining at least one compartment of the box spar.

[0006] An exemplary method includes placing a one-piece forward skin on an assembly fixture, the one-piece forward skin defining an upper surface and a lower surface of a leading edge slat, wherein the one-piece forward skin extends between a forward end and a rearward end of the leading edge slat, and wherein the fixture has a cavity shaped to receive at least a portion of the upper surface and the lower surface. The exemplary method also includes coupling a box spar to an inner surface of the one-piece forward skin while the one-piece forward skin is in the fixture, wherein the box spar includes lateral walls extending away from the inner surface, the lateral walls defining at least one compartment of the box spar. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 An aircraft in which the examples disclosed herein may be implemented.

[0008] Figure 2 is a perspective view of a known leading edge slat.

[0009] Figure 3A and Figure 3B yes Figure 2 The known leading edge slats are along Figure 2 A cross-sectional view along line 3-3 is shown.

[0010] Figure 3C yes Figures 2 to 3B Rear perspective view of a known leading edge slat.

[0011] Figure 4 is a perspective view of an exemplary leading edge slat in accordance with the teachings of the present disclosure.

[0012] Figure 5 yes Figure 4 An exemplary leading edge slat is along Figure 4 A cross-sectional view along line 5-5 is shown.

[0013] Fig. 6A yes Figure 4 and Figure 5 Detailed perspective view of an exemplary leading edge slat.

[0014] Figure 6B yes Figures 4 to 6A Another detailed perspective view of an exemplary leading edge slat of FIG.

[0015] Figure 6C yes Figures 4 to 6B Detailed side view of an exemplary leading edge slat having an exemplary alternative machined trailing edge design.

[0016] Fig. 7A and Figure 7B is a detailed perspective view of an exemplary rib configuration that may be implemented in the examples disclosed herein.

[0017] Figure 7C and Fig.7D They are Fig. 7A and Figure 7B A cross-sectional view of an exemplary rib.

[0018] Figure 8 yes Figures 4 to 7D A perspective view of an exemplary one-piece forward skin of an exemplary leading edge slat.

[0019] Fig. 9 yes Figures 4 to 8 Rear view of an exemplary leading edge slat.

[0020] Fig.10 is a cross-sectional view of a fixture that can be used to make the examples disclosed herein.

[0021] Fig.11 is a flow chart representing an exemplary method of making the examples disclosed herein.

[0022] Fig.12 is a front perspective view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0023] Fig.13 is a front elevation view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0024] Fig.14 It is a rear elevation view.

[0025] Fig.15 is a right side view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0026] Fig.16 is a left side view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0027] Fig.17 is a top view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0028] Fig.18 is a bottom view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0029] Fig.19 is a front perspective view of an aerodynamic structure used for an aircraft.

[0030] Fig. 20 is a front elevation view of an aerodynamic structure for an aircraft.

[0031] Fig.21 is a rear elevation view of an aerodynamic structure for an aircraft.

[0032] Fig. 22is a right side view of the aerodynamic structure used for an aircraft.

[0033] Fig.23 It is a left side view of the aerodynamic structure used for an aircraft.

[0034] Fig.24 is a top view of an aerodynamic structure used in an aircraft.

[0035] Fig.25 is a bottom view of the aerodynamic structure used for an aircraft.

[0036] The drawings are not drawn to scale. On the contrary, in the drawings, the thickness of the layer or region can be enlarged. Generally, the same reference numerals will be used throughout the drawings and the attached written description to represent the same or similar parts. As used in the present disclosure, the statement that any part is located (e.g., positioned on, located at, set on or formed on, etc.) on another part in any way indicates that the referenced part is in contact with another part, or the referenced part is above another part, with one or more intermediate parts located between them. Connection references (e.g., attachment, connection, connection and engagement) should be interpreted broadly, and unless otherwise specified, may include intermediate members between element sets and relative movement between elements. Therefore, connection references do not necessarily represent that two elements are directly connected and are in a fixed relationship with each other. The statement that any part "contacts" another part means that there is no intermediate part between the two parts. Although the drawings show layers and regions with clear lines and boundaries, some or all of these lines and / or boundaries may be idealized. In fact, boundaries and / or lines may be invisible, mixed and / or irregular.

[0037] Descriptors "first," "second," "third," etc., are used herein when identifying multiple elements or components that can be referred to individually. Unless otherwise specified or understood based on the context of its use, such descriptors are not intended to attribute any meaning of priority, physical order, or arrangement in a list or chronological order, but are merely used as labels for referring to multiple elements or components individually to facilitate understanding of the disclosed examples. In some examples, the descriptor "first" can be used to refer to an element in a specific embodiment, while the same element can be referred to in the claims by a different descriptor such as "second" or "third." In this case, it should be understood that such descriptors are only used to facilitate reference to multiple elements or components. DETAILED DESCRIPTION

[0038] A continuous skin leading edge slat is disclosed. Some known leading edge slats employ an outer skin that is positioned and assembled together via an internal structure. Specifically, in some known embodiments, the outer front skin is aligned with a wedge via an internal spar or spar bracket (e.g., a C-shaped or J-shaped spar bracket), which defines a joint between the outer front skin and the wedge. However, this joint is typically located at an aerodynamic surface, thereby causing a geometric discontinuity on the aerodynamic surface. As a result, the corresponding drag coefficient may be relatively high, and therefore significant fuel consumption and costs may be encountered.

[0039] The examples disclosed herein enable effective implementation of the aerodynamics of a leading edge slat (e.g., a leading edge slat assembly) or any other suitable type of aircraft control surface. The exemplary leading edge slat includes a front skin, wherein a metal bonding assembly is coupled to the one-piece front skin. Specifically, the exemplary one-piece front skin defines an upper outer surface and a lower outer surface of the leading edge slat, and the one-piece front skin extends between the front end and the rear end of the leading edge slat. In the examples disclosed herein, the box spar of the above-mentioned metal bonding assembly is coupled to the inner surface of the one-piece front skin. The box spar includes a lateral wall extending away from the inner surface, and the lateral wall defines at least one compartment of the box spar so as to provide structural support for the one-piece front skin. The one-piece front skin results in a relatively smooth and continuous outer surface, and thus provides a reduced drag coefficient. In addition, the examples disclosed herein can reduce costs and the number of assembled parts, and thereby reduce the total weight associated with the leading edge slat.

[0040] In some examples, the spar coupled to the one-piece front skin can be T-shaped, J-shaped, I-shaped or box-shaped. In some examples, the ribs extend between the one-piece front skin and the box-shaped spar. In some examples, the box-shaped spar is connected to the inner surface of the one-piece front skin via an epoxy resin adhesive. In some examples, the trailing edge of the leading edge slat and / or the one-piece front skin is machined to define a relatively thin and / or wavy distal trailing edge of the slat. In some examples, the leading edge slat includes a concave skin assembled and / or coupled to the leading edge slat, which has a concave opening for approaching the inside of the leading edge slat. In some examples, a fixture formed to receive the one-piece front skin is implemented to promote the connection of the metal bonding assembly with the one-piece front skin.

[0041] As used herein, the term "box spar" refers to a spar and / or spar structure having a rectangular shape and / or an overall characteristic shape. Thus, the term "box spar" may refer to a spar structure comprising a T-shaped, J-shaped or I-shaped portion and defining at least one open compartment (e.g., a five-sided open compartment). As used herein, the terms "metal bonding assembly" and "wedge-shaped assembly" refer to an assembly of components used to hold, mount and / or align other components of a leading edge slat. As used herein, in the context of an aerodynamic surface / component (e.g., an outer aerodynamic skin), the term "single-piece" means that the aerodynamic surface / component is relatively continuous and does not exhibit significant geometric discontinuities, component transitions, gaps and / or seams.

[0042] Figure 1 An exemplary aircraft 100 that can implement the examples disclosed herein is shown. In the illustrated example, the aircraft 100 includes a horizontal tail 102, a vertical tail 103, and a wing (e.g., a fixed wing) 104 attached to a fuselage 106. The wing 104 of the illustrated example has an engine 107 and a control surface (e.g., flaps, ailerons, tabs, etc.) 108, some of which are located at the trailing edge or leading edge of the wing 104. The control surface 108 can be displaced or adjusted (e.g., deflected, etc.) to provide lift during takeoff, landing, and / or flight maneuvers. In some examples, the control surfaces 108 operate (i.e., shift) independently of each other. The exemplary control surfaces 108 include a trailing edge flap (e.g., a rotatable flap) 114, an aileron 118, a flaperon 120, a leading edge Krueger flap 121, and a leading edge slat 127. In this example, horizontal tail 102 includes elevator 122, and vertical tail 103 includes rudder 123. Wing 104 also defines upper and lower surfaces 124, 126, respectively (eg, upper and lower sides, upper and lower aerodynamic surfaces, etc.).

[0043] To control the flight of the aircraft 100, the control surfaces 108 change the lift and pitch of the aircraft 100. The control surfaces 108 of the illustrated example also play a role in controlling the speed of the aircraft 100. Any of the control surfaces 108 of the illustrated example can be independently moved (e.g., deflected) to control the load distribution in different directions over the wing 104 to guide the movement of the aircraft 100. In some examples, during cruising of the aircraft 100, the control surfaces 108 are moved to reduce the drag of the aircraft 100.

[0044] The examples disclosed herein may be applied to any control surface 108, leading edge Krueger flap 121, slat 127, flap 114, aileron 118, flaperon 120, horizontal tail 102, vertical tail 103, wing 104, fuselage 106, engine 107, and / or any other external or outboard structure (e.g., horizontal stabilizer, wing strut, engine strut, canard stabilizer, etc.) of the aircraft 100. Additionally or alternatively, in some examples, the fuselage 106 has control surfaces that can be deflected to change flight handling characteristics during cruise and / or takeoff of the aircraft 100.

[0045] Steering Figure 2 , showing a known slat 200. In this known embodiment, the slat 200 includes an upper outer surface 201, which in turn includes a first upper surface 202 and a front skin or front surface 206. In addition, the upper outer surface 201 of the slat 200 includes a first line 208 and a second line 210 (e.g., a fastener line, a seam line, a geometric discontinuity, etc.), which subdivide the first upper surface 202 and the front skin 206. The slat 200 also includes a blockout 216, which covers the opposite lateral ends of the slat 200.

[0046] In operation, during flight, air flows along the upper outer surface 201. However, due to the first line 208 and the second line 210, this airflow may be interrupted and / or separated from the first upper surface 202 and the front skin 206. As a result, the drag coefficient associated with the leading edge slat 200 may be large. In turn, additional fuel costs and / or unfavorable flight characteristics may be experienced. In contrast, the examples disclosed herein enable a smooth continuous surface with minimal or no airflow disturbance, thereby reducing the drag coefficient. In addition, the examples disclosed herein enable fewer components, which can also lead to a reduction in overall weight.

[0047] Figure 3A and Figure 3B yes Figure 2 The known leading edge slat 200 is along Figure 2 A cross-sectional view of line 3-3 is shown. Figure 3A , first upper surface 202 and front skin 206 are separated via line 210, while front skin 206 is attached to front beam 302 via line 208. Thus, line 210 represents a seam or gap between first upper surface 202 and front skin 206, and both lines 208, 210 define corresponding rows of fasteners that attach front skin 206 to front beam 302. As a result, the rows of fasteners described above may increase the drag coefficient.

[0048] To provide support for the front skin 206, the front beam 302 is fastened to the front skin 206 at flanges 304 (hereinafter flanges 304a, 304b, etc.). In addition, the concave skin 306 spans the bottom area of ​​the leading edge slat 200, and the core 309 extends from the spar (e.g., spar wall, spar bracket, etc.) 310 to the top end 308 that at least partially defines the distal end of the leading edge slat 200.

[0049] Figure 3B yes Figure 3A Detailed view of area A shown. Figure 3B In the view shown in FIG. 3 , the spar 310 is generally J-shaped or C-shaped, and is aligned with the surface and recessed into the skin 306 by flanges 314 (hereinafter 314a, 314b, etc.). In addition, the spar 310 abuts the core 309.

[0050] Figure 3C yes Figures 2 to 3B 306 is a rear perspective view of a known leading edge slat 200. In this known embodiment, a removable access door 320 is positioned on the recessed skin 306 to access the interior of the known leading edge slat 200.

[0051] Figure 4 is a perspective view of an exemplary leading edge slat 400 according to the teachings of the present disclosure. Figure 1 The slat 400 is shown implemented on the leading edge of the wing 104 and includes a single-piece forward skin 402 and closed surfaces or walls 404, 406. In this example, during flight of the aircraft 100, the slat 400 moves (e.g., translates, rotates, etc.) relative to the wing 104 to direct the movement and / or aerodynamics of the aircraft 100 during flight.

[0052] In order to provide favorable aerodynamic characteristics (e.g., relatively low drag coefficient, etc.) during flight of the aircraft 100, the one-piece front skin 402 is relatively continuous (e.g., having a relatively uninterrupted surface with few or no seams and / or surface interruptions). In the illustrated example, the one-piece front skin 402 extends substantially from a front end (i.e., front end) 408 of the leading edge slat 400 to a rear end (i.e., rear end) 410. In addition, the one-piece front skin 402 at least partially defines (e.g., completely defines) an upper surface 412 and a lower surface 414 of the leading edge slat 400. In other words, the exemplary one-piece front skin 402 is curved and / or bent and spans the entire streamwise length of the leading edge slat 400 while at least partially covering the top and bottom sides of the leading edge slat 400.

[0053] By implementing the examples disclosed herein, in this example, the fastener row 420 can be used to install and secure the single-piece front skin 402 to the internal components and / or structure of the leading edge slat 400, and is arranged in the general flow direction of the leading edge slat 400. Specifically, the fastener row 420 is arranged in the aerodynamically effective flow direction, rather than as Figures 2 to 3C The known leading edge slat 200 is shown extending in the lateral span direction. In other words, the exemplary continuous single-piece front skin 402 combines with minimal surface features and / or irregularities to define most of the external shape of the leading edge slat 400. Due to the relatively smooth and continuous profile of the single-piece front skin 402, the desired flow characteristics can be experienced during the flight of the aircraft 100. In some examples, the fastener row 420 may not be in the flow direction (e.g., swept wing configuration, etc.). Additionally or alternatively, the fastener row 420 is aligned with the flow direction at approximately 0-10 degrees.

[0054] Figure 5 yes Figure 4 The exemplary leading edge slat 400 is arranged along Figure 4 5-5. In this example, the slat 400 includes the above-described one-piece front skin 402, shown coupled and / or bonded to a metal bond assembly 502, a recessed skin (e.g., a recessed bracket, a recessed support, etc.) 504 having a mounting wall (e.g., a mounting flange, a mounting tab, etc.) 506, and a recessed bracket 507. In this example, the metal bond assembly 502 includes a box spar (e.g., a wedge-shaped box spar, a machined box spar) 508, a core 510, and a tip (e.g., a converging tip, a canted tip, a wedge-shaped tip, a wedge, a metal tip, etc.) 512. Additionally or alternatively, the slat 400 includes a lower skin (e.g., a lower wall, a lower edge, a lower panel, a sheet metal panel, etc.) 514. In the example shown, fasteners 516 couple the recessed skin 504, the box spar 508, and the one-piece front skin 402 together. In some other examples, fasteners 516 are not implemented (e.g., the ribs are coupled to the one-piece forward skin 402 via a bonding operation for support and / or increased rigidity). Additionally or alternatively, the recessed skin 504 and the recessed bracket 507 are integral, such that fasteners 516 are eliminated. Furthermore, the recessed skin 504 at least partially defines an interior cavity.

[0055] In order to provide structural support and mount the internal and external components of the leading edge slat 400, the exemplary box spar 508 is generally box-shaped, cup-shaped and / or rectangular in shape and includes a lateral wall 520 extending from a bottom wall 522 and an inner surface of the single-piece front skin 402. In other words, the box spar 508 is, for example, generally U-shaped. As a result, the box spar 508 forms a second torsion spanwise unit for the first front main unit slat, thereby increasing the overall stiffness. In addition, the box spar 508 has a flange (e.g., mounting flange, support foot, etc.) 524 extending outward from the lateral wall 520 and contacting the inner surface of the single-piece front skin 402 to further strengthen the leading edge slat 400. In this example, one of the lateral walls 520 is adjacent to and aligned with the core 510. In this example, the box spar 508 is used to align the recessed bracket 507, and then align the recessed skin 504, thereby providing additional internal support to the leading edge slat 400. Therefore, the lateral walls 520 and the bottom wall 522 of the box spar 508 define a cavity or compartment (e.g., an internal cavity, a partially open cavity) 526 disposed therein. Specifically, the plurality of cavities 526 are arranged along the span direction (into the leading edge slot 400) of the leading edge slot 400. Figure 5 of pages) are arranged consecutively.

[0056] The exemplary metal bonding assembly 502 and / or the box spar 508 are positioned on the inner surface of the one-piece front skin 402, and the lower skin 514, the core 510 and / or the closed surface or panel are also positioned on the inner surface or relative to the inner surface. In some examples, the lower skin 514 is implemented as a wall / panel that spans the assembly and / or placement of the box spar 508, the core 510 and the top end 512. In this example, both the box spar 508 and the core 510 are adjacent to the lower skin 514. In other words, the lower skin 514 can at least partially cover the box spar 508 and the core 510. Additionally or alternatively, the top end 512 is also adjacent to the lower skin 514 and / or covered by the lower skin. In some other examples, a welding process is used to connect the metal bonding assembly 502 and / or the box spar 508 to the inner surface.

[0057] Fig. 6A yes Figure 4 and Figure 5Detailed perspective view of an exemplary leading edge slat 400, wherein the one-piece front skin 402 is removed for clarity. In the illustrated example, a box spar 508, a core 510, a top end 512, and a lower skin 514 are shown. In addition, the exemplary box spar 508 includes an opening 604, which can be used to receive fasteners to connect the box spar 508 to the one-piece front skin 402 during the assembly of the leading edge slat 400. In addition, a plurality of chambers 526 defined by the lateral walls 520 are shown as being arranged generally along the span length of the exemplary leading edge slat 400. In other words, in this example, the chambers 526 are arranged along a single axis or direction. However, additionally or alternatively, the chambers 526 can be arranged along any other direction (e.g., along the flow direction, diagonally, etc.). In some examples, box spar 508 includes tabs or flanges 605 for retaining (eg, holding, positioning, or securing) core 510 toward an inner surface of single-piece forward skin 402 .

[0058] If available Fig. 6A As seen in the illustrated example of , both the core 510 and the tip 512 have inclined or beveled portions and / or shapes. Specifically, the core 510 and the tip 512 have inclined surfaces 606, 610, respectively. In this example, the inclined surfaces 606, 610 are generally aligned with each other (e.g., oriented to be within an angle of about 5 degrees relative to each other), and thus can define a single inclined profile of the leading edge slat 400.

[0059] In some examples, the tip 512, the core 510, and / or the lower skin 514 are integral with the box spar 508. In other words, the tip 512, the core 510, and / or the lower skin 514 may be implemented as machined features or details (e.g., implemented as a combination of ribs, stiffeners, a grid of ribs or stiffeners, etc.). For example, the tip 512, the core 510, and / or the lower skin 514 are defined by panels and / or portions of the box spar 508 that are adjacent to and aligned with the core 510. In some such examples, the tip 512 may be machined to obtain a reduced thickness and / or a sloped edge to reduce drag experienced at relatively high speeds of the aircraft 100.

[0060] Figure 6B yes Figures 4 to 6ADetailed perspective view of a horizontal flip of an exemplary leading edge slat 400 showing an exemplary one-piece front skin 402. In this particular example, the machined trailing edge is defined after a bonding (e.g., metal bonding) operation. In the illustrated example, the top end 512 is shown as being disposed between the lower skin 514 and the one-piece front skin 402. For example, after bonding, the top end 512 and the one-piece front skin 402 are machined to define machined surfaces (e.g., inclined surfaces) 620, 622, respectively. In this example, the machined surface 622 defines the trailing edge surface. In some examples, the contours of the machined surfaces 620, 622 are designed to substantially match each other (e.g., the same or similar cutting angles, aligned matching intersections therebetween, etc.).

[0061] Figure 6C yes Figures 4 to 6B Detailed side view of a horizontal flip of an exemplary leading edge slat 400 having an exemplary alternative machined trailing edge design. Specifically, Figure 6C The example shown depicts a bonded trailing edge implementation in which a chamfer is manufactured into the skin detail prior to bonding (e.g., no machining after bonding). In this example, the tip 512 includes a machined surface 632 located on the single-piece front skin 402. Figure 6B In contrast to the example of , lower skin 514 has a straight (eg, non-sloped) portion 634 .

[0062] Fig. 7A and Figure 7B is a detailed perspective view of an exemplary rib configuration that may be implemented in the examples disclosed herein. Fig. 7A , a mounting rib 700 is shown mounted relative to the core 510 and the box spar 508. Specifically, the exemplary mounting rib 700 is used to pivotally and / or translationally couple the exemplary leading edge slat 400 to the corresponding wing 104. The mounting rib 700 of the illustrated example includes a connecting portion 702, which includes a distal end 704 and one or more mounting holes 706. In addition, the mounting rib 700 also includes a support portion or base 708, which is coupled (e.g., fastened, adhered, etc.) to a clamp 710. In turn, the clamp 710 of the illustrated example is coupled to the box spar 508 (e.g., coupled to the box spar 508 via fasteners). In this example, the opening 604 enables access to fasteners (e.g., nuts, screws, etc.) inside the box spar 508 during manufacture or maintenance of the leading edge slat 400. For example, fasteners for fastening the mounting rib 700 to the box spar 508 can be accessed via the opening 604. In other examples, the nut plates used to couple the mounting ribs 700 may be mounted to the box spar 508 after the box spar 508 has been joined to the single-piece forward skin 402 .

[0063] Figure 7BAn exemplary structural rib 720 is depicted. The structural rib 720 is similar to Fig. 7A 700, but is instead implemented to reinforce the leading edge slat 400 without being coupled to other components of the aircraft 100. Specifically, the exemplary structural rib 720 is used to provide rigidity to the leading edge slat 400 while allowing the leading edge slat 400 to be relatively light weight for flight of the aircraft 100. In this example, the structural rib 720 is coupled to the box spar 508 at the alignment wall 724.

[0064] Figure 7C and Fig.7D They are Fig. 7A and Figure 7B A cross-sectional view of the mounting rib 700 and the structural rib 720. Figure 7C , a cross-sectional view of the mounting rib 700 is shown. In this example, at least one of the mounting rib 700 and the clip 710 is mounted to the single-piece front skin 402 via an upper fastener 730 at the upper surface 412. Likewise, at least one of the mounting rib 700 and the clip 710 is mounted to the single-piece front skin 402 via a lower fastener 732 at the lower surface 414. In addition, the mounting rib 700 is mounted and / or coupled to the recessed skin 504 and the box spar 508 via fasteners 734. As a result, the single-piece front skin 402 and generally the leading edge slat 400 are structurally strengthened. In addition, the examples disclosed herein enable the mounting rib 700 to extend almost completely through the interior volume of the single-piece front skin 402 and also to be substantially aligned with the interior geometry of the single-piece front skin 402, which may be structurally advantageous due to the relatively high loads of the leading edge slat 400.

[0065] Go to Fig.7D , depicting structural rib 720. Similar to mounting rib 700, structural rib 720 is coupled to single-piece forward skin 402 via upper fastener 730 and lower fastener 732, and is coupled to box spar 508 via fastener 734. Also, tab arms or protrusions 736 of structural rib 720 extend beyond the openings of box spar 508 and / or recessed skin 504 for alignment and / or additional structural stiffness. Similar to mounting rib 700, structural rib 720 extends through a majority of the interior volume of single-piece forward skin 402.

[0066] Figure 8 It is a combination of the above Figures 4 to 7D A perspective view of a one-piece forward skin 402 of an exemplary leading edge slat 400 is shown and described. Figure 8 As seen in the example shown, exemplary one-piece front skin 402 includes a top portion 801 , a curved portion 802 , a rear region 803 , and a bottom portion 804 .

[0067] In this example, the one-piece front skin 402 is at least partially composed of an aluminum alloy (e.g., aluminum alloy 7075, etc.). In addition, the one-piece front skin 402 is also bent to define both the upper surface 412 and the lower surface 414 described above. In some examples, an anodized finish and / or a bonded primer finish inner / inner mold line (IML) can be implemented. In some examples, the IML includes a reduced thickness area, which can be reduced in thickness via machining or alternatively chemical milling. In some examples, laminated skins, reinforcement plates, etc. can be implemented to increase the thickness of the IML. However, any other material and / or finish can be implemented instead.

[0068] Although in this example Figure 8 The one-piece front skin 402 is shown as being curved in two dimensions, but the one-piece front skin 402 may alternatively be curved in three dimensions (e.g., compound curvature, multiple bends, etc.). In some such examples, the one-piece front skin 402 may be curved and / or bent to define closed surfaces and / or lateral walls, etc.

[0069] Fig. 9 yes Figures 4 to 8 400. In the example shown, the core 510 and the recessed skin 504 are shown as having ribs 700, 720. The exemplary recessed skin 504 includes non-removable portions 902 interspersed between removable portions (e.g., removable panels, removable doors, etc.) 904. The exemplary removable portions 904 may be implemented to provide access to the interior of the leading edge slat 400 for assembly, disassembly, and / or repair, etc. For example, referring to Figure 5 , the removable portion of the recessed skin 504 can provide access to the internal cavity of the leading edge slat 400. In this example, the shape of the removable portion 904 is generally trapezoidal. However, any suitable shape or geometry can be implemented alternatively. In some examples, the sensor is mounted near the non-removable portion 902 and / or the removable portion 904.

[0070] Fig.10 1 is a cross-sectional view of a fixture 1002 that may be used to produce (e.g., assemble) examples disclosed herein. In the illustrated example, fixture 1002 includes a contoured surface or cavity 1004 that is complementarily shaped to receive an outer surface of single-piece front skin 402. In this example, single-piece front skin is placed on contoured surface 1004 prior to assembling metal bonding assembly 502 to single-piece front skin 402. In some examples, vacuum bag 1010 may be implemented.

[0071] Fig.11 1 is a flow chart representing an exemplary method 1100 for producing the examples disclosed herein. The exemplary method 1100 begins by manufacturing and assembling the slat 400 onto the aircraft 100 .

[0072] At block 1102, in some examples, a one-piece front skin 402 is manufactured. Specifically, the exemplary one-piece front skin 402 is produced in a sheet metal manufacturing process. In other examples, the one-piece front skin 402 is cast, extruded, 3-D printed, and / or machined.

[0073] At block 1104, one-piece forward skin 402 is placed in jig 1002. Specifically, one-piece forward skin 402 is nested into contoured surface 1004 so that one-piece forward skin is protected from damage and / or excessive displacement when components / assemblies are assembled, bonded, and / or coupled to one-piece forward skin 402. In this example, jig 1002 is shaped to receive and align multiple exterior surfaces of one-piece forward skin 402.

[0074] At block 1106, in some examples, components such as core 510 or lower skin 514 are assembled / coupled to box spar 508 before box spar 508 is joined / coupled to single-piece forward skin 402. Lower skin 514 may be used to hold core 510 and / or tip 512 to box spar 508.

[0075] At block 1108, box spar 508 is coupled / bonded to the inner surface of single-piece front skin 402 while single-piece front skin 402 is held in fixture 1002. In this example, an epoxy adhesive (e.g., an epoxy film adhesive cured at approximately 250 degrees Fahrenheit) is bonded to the box spar 508. EA-9696, Adhesives, Adhesive, room temperature or 350 degrees Fahrenheit curing adhesive, etc.) is used to bond the box spar 508 to the single-piece front skin 402. However, any suitable joining method (e.g., mechanical fastening, chemical fastening, welding, etc.) may alternatively be used.

[0076] At block 1110, in some examples, the trailing edge is trimmed. Additionally or alternatively, the trailing edge may be machined.

[0077] At block 1112 , in some examples, the ribs and recesses of the slat 400 are fastened and / or coupled, and the process ends.

[0078] Fig.12 is a front perspective view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0079] Fig.13 is a front elevation view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0080] Fig.14 It is a rear elevation view.

[0081] Fig.15 is a right side view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0082] Fig.16 is a left side view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0083] Fig.17 is a top view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0084] Fig.18 is a bottom view of fasteners used in an aerodynamic structure of an aircraft, wherein the fasteners are arranged in rows.

[0085] Fig.19 is a front perspective view of an aerodynamic structure used for an aircraft.

[0086] Fig. 20 is a front elevation view of an aerodynamic structure for an aircraft.

[0087] Fig.21 is a rear elevation view of an aerodynamic structure for an aircraft.

[0088] Fig. 22 is a right side view of the aerodynamic structure used for an aircraft.

[0089] Fig.23 It is a left side view of the aerodynamic structure used for an aircraft.

[0090] Fig.24 is a top view of an aerodynamic structure used in an aircraft.

[0091] Fig.25 is a bottom view of the aerodynamic structure used for an aircraft.

[0092] Example 1 includes a slat. The slat includes a one-piece front skin and a box spar, the one-piece front skin defining an upper outer surface and a lower outer surface of the slat, wherein the one-piece front skin extends between a front end and a rear end of the slat, and the box spar is coupled to an inner surface of the one-piece front skin, wherein the box spar includes a lateral wall extending away from the inner surface of the one-piece front skin, wherein the lateral wall defines at least one compartment of the box spar.

[0093] Example 2 includes a leading edge slat as defined in Example 1, further comprising a rib extending between the single-piece forward skin and the box spar.

[0094] Example 3 includes a leading edge slat as defined in Example 2, wherein the box spar includes holes for fasteners to couple the ribs to the one-piece forward skin.

[0095] Example 4 includes a leading edge slat as defined in any one of Examples 1 to 3, wherein the box spar includes a flange to retain the core to the inner surface.

[0096] Example 5 includes a leading edge slat as defined in any one of Examples 1 to 4, wherein the box spar is coupled to the inner surface via an epoxy adhesive.

[0097] Example 6 includes a leading edge slat as defined in any of Examples 1 to 5, wherein the one-piece forward skin includes a machined trailing edge of the one-piece forward skin that extends beyond a top end adjacent the core.

[0098] Example 7 includes a leading edge slat as defined in Example 6, further comprising an inclined surface at the tip, wherein the machined trailing edge and the inclined surface are oriented within an angle of approximately 5 degrees relative to each other.

[0099] Example 8 includes a leading edge slat as defined in any of Examples 1 to 7, further comprising a recessed skin coupled to the one-piece forward skin and the box spar, wherein the recessed skin includes a removable recessed panel to access an interior of the leading edge slat.

[0100] Example 9 includes a wing of an aircraft. The wing includes a fixed wing portion defining an aerodynamic surface of the aircraft, and a leading edge slat movably coupled to the fixed wing portion. The leading edge slat includes a single-piece front skin and a box spar, the single-piece front skin defining an upper outer surface and a lower outer surface of the leading edge slat, wherein the single-piece front skin extends between a front end and a rear end of the leading edge slat, the box spar is coupled to an inner surface of the single-piece front skin, the box spar includes lateral walls extending away from the inner surface and defining at least one compartment of the box spar.

[0101] Example 10 includes a wing as defined in Example 9, wherein the leading edge slat further includes at least one rib extending between the single-piece forward skin and the box spar.

[0102] Example 11 includes a wing as defined in Example 9 or 10, wherein the leading edge slat further includes fasteners to couple the single-piece forward skin to the box spar.

[0103] Example 12 includes a wing as defined in Example 10 or 11, wherein the leading edge slat is movably coupled to the fixed wing portion via at least one rib.

[0104] Example 13 includes a wing as defined in any of Examples 10 to 12, wherein the at least one rib is coupled to an upper surface and a lower surface of the one-piece forward skin.

[0105] Example 14 includes a wing as defined in any of Examples 9 to 13, wherein the one-piece front skin includes a machined trailing edge extending beyond a top end adjacent the core.

[0106] Example 15 includes a method for an aircraft wing, the method comprising placing a single-piece front skin on an assembly fixture, wherein the single-piece front skin defines an upper surface and a lower surface of a leading edge slat, wherein the single-piece front skin extends between a forward end and a rearward end of the leading edge slat, and wherein the fixture has a cavity shaped to receive at least a portion of the upper surface and the lower surface. The method also includes coupling a box spar to an inner surface of the single-piece front skin while the single-piece front skin is in the fixture, the box spar including lateral walls extending away from the inner surface, the lateral walls defining at least one compartment of the box spar.

[0107] Example 16 includes the method as defined in Example 15, further comprising coupling the core to at least one of the single-piece forward skin and the box spar.

[0108] Example 17 includes a method as defined in Example 15 or 16, wherein coupling the box spar to the one-piece forward skin includes applying an epoxy adhesive between the box spar and the inner surface.

[0109] Example 18 includes the method as defined in any of Examples 15 to 17, wherein coupling the box spar to the inner surface includes coupling the box spar to the rib via fasteners.

[0110] Example 19 includes the method as defined in Example 18, further comprising coupling the rib to the one-piece forward skin via fasteners.

[0111] Example 20 includes a method as defined in any of Examples 15 to 18, wherein coupling the box spar to the single-piece forward skin includes coupling the box spar to the rib via a first fastener, and wherein the rib is coupled to the single-piece forward skin via a second fastener.

[0112] From the foregoing it will be appreciated that exemplary methods, apparatus and articles of manufacture have been disclosed that enable aerodynamically efficient control surfaces (eg, leading edge slats). The examples disclosed herein also enable cost-effective and lightweight implementations of control surfaces.

[0113] Although certain example methods, apparatus, and articles of manufacture have been disclosed herein, the scope of coverage of this disclosure is not limited thereto. On the contrary, this disclosure covers all methods, apparatus, and articles of manufacture falling fully within the scope of the claims of this disclosure.

[0114] The following claims are incorporated into this detailed description by this reference, wherein each claim independently serves as a separate embodiment of the present disclosure. Although the examples disclosed herein are shown as being related to leading edge slats, the examples disclosed herein may be applied to any suitable aerodynamic application or structure. In addition, any suitable alternative incorporation techniques or methods may be implemented alternatively.

Claims

1. A leading edge slat (400) for an aircraft, the leading edge slat comprising: a one-piece forward skin (402) defining an upper outer surface (412) and a lower outer surface (414) of the slat, wherein the one-piece forward skin extends between a forward end and a rearward end of the slat; and a box spar (508) coupled to an inner surface of the one-piece forward skin, wherein the box spar includes lateral walls (520) extending away from the inner surface, the lateral walls defining at least one compartment (526) of the box spar, wherein the box spar (508) includes a flange (605) to retain a core (510) to the inner surface, and wherein the core (510) abuts and is aligned with one of the lateral walls (520) of the box spar (508) and extends to a top end (512) that at least partially defines the aft end of the leading edge slat (400); and A recessed skin (504) is coupled to the one-piece forward skin and the box spar, wherein the recessed skin includes a removable recessed panel to access an interior of the leading edge slat.

2. The leading edge slat of claim 1, further comprising a rib (700, 720) extending between the one-piece forward skin and the box spar.

3. The leading edge slat according to claim 2, wherein: The box spar includes holes (604) for fasteners to couple the ribs to the one-piece forward skin.

4. The leading edge slat according to claim 1, wherein: The box spar is coupled to the inner surface via an epoxy adhesive.

5. The leading edge slat of claim 1 further comprising a machined trailing edge (622) of the one-piece forward skin, the machined trailing edge extending beyond a top end (512) adjacent the core (510).

6. The leading edge slat according to claim 5, further comprising an inclined surface (620, 622) of the top end, wherein: The machined trailing edge and the angled surface are oriented within an angle of approximately 5 degrees relative to each other.

7. A wing (104) of an aircraft, the wing comprising: a fixed wing section defining an aerodynamic surface of said aircraft; as well as A slat according to any one of claims 1 to 6, movably coupled to the fixed wing section.

8. The wing according to claim 7, wherein: The leading edge slat also includes a plurality of ribs extending between the one-piece forward skin and the box spar.

9. The wing according to claim 7, wherein: The leading edge slat also includes fasteners to couple the one-piece forward skin to the box spar.

10. The wing according to claim 8, wherein: The slat is movably coupled to the fixed wing portion via one of the ribs.

11. A wing according to any one of claims 7 to 10, wherein: The one-piece forward skin includes a machined trailing edge extending beyond a top end adjacent the core.

12. A method for an aircraft wing comprising: placing a one-piece forward skin on an assembly fixture (1002), the one-piece forward skin defining an upper surface and a lower surface of a leading edge slat, wherein the one-piece forward skin extends between a forward end and a rearward end of the leading edge slat, and wherein the assembly fixture has a cavity (1004) shaped to receive at least a portion of the upper surface and the lower surface; and coupling a box spar to an inner surface of the one-piece forward skin while the one-piece forward skin is in the assembly fixture, the box spar including lateral walls extending away from the inner surface, the lateral walls defining at least one compartment of the box spar, wherein the box spar (508) includes a flange (605) to retain a core (510) to the inner surface, and wherein the core (510) abuts and is aligned with one of the lateral walls (520) of the box spar (508) and extends to a top end (512) that at least partially defines the aft end of the leading edge slat (400); and A recessed skin (504) is coupled to the one-piece forward skin and the box spar, wherein the recessed skin includes a removable recessed panel to access an interior of the slat.

13. The method of claim 12, further comprising coupling a core to at least one of the one-piece forward skin and the box spar.

14. The method according to claim 13, wherein: Coupling the box spar to the inner surface of the one-piece forward skin includes applying an epoxy adhesive between the box spar and the inner surface.

15. The method according to claim 13, wherein: Coupling the box spar to the inner surface of the one-piece forward skin includes coupling the box spar to a rib via fasteners.

16. The method of claim 15, further comprising coupling the rib to the one-piece forward skin via fasteners.

17. The method according to any one of claims 13 to 16, wherein: Coupling the box spar to the inner surface of the one-piece forward skin includes coupling the box spar to a rib via a first fastener, and wherein the rib is coupled to the one-piece forward skin via a second fastener.

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