Method and apparatus for repairing composite airfoil structure

Abstract

The invention relates to a method and apparatus for repairing a composite airfoil structure. Systems, devices, articles of manufacture, and methods for repairing a semi-shell wing are disclosed that include a doubler plate configured to be bonded to a skin of a semi-shell wing by a first adhesive, the doubler plate having a profile substantially complementary to a profile of a leading edge of the semi-shell wing; and a tape layer positioned at least partially along at least a portion of an interface between the doubler plate edge and the skin leading edge.

Description

Technical Field

[0001] The present disclosure relates generally to aircraft and, more particularly, to methods and apparatus for repairing composite airfoil structures. Background Art

[0002] Many aircraft use monocoque and / or semi-monocoque structures to bear major stresses and / or maintain the rigidity of the aircraft's wing leading edges, winglets and / or wingtips. Monocoque and / or semi-monocoque structures can be easily damaged by impacts and need to be repaired to meet the aircraft's aerodynamic requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0003] Figure 1 is a perspective view of an example aircraft having an example repairable structure in accordance with the teachings of the present disclosure.

[0004] Figure 2 yes Figure 1 A perspective view of an example winglet of an example aircraft in an operational or undamaged condition.

[0005] Figure 3 yes Figure 1 and Figure 2 A perspective view of an example winglet of an example aircraft in an example inoperable or damaged condition.

[0006] Figure 4 Repaired using a repair doubler according to the teachings of this disclosure Figure 3 A perspective view of an example winglet.

[0007] Figure 5 yes Figure 4 A perspective view of an example winglet in an example repaired or operational condition.

[0008] Figure 6 yes Figure 5 Example cross-section of an example repair doubler and an example winglet.

[0009] Figure 7 is a cross-sectional view of another example repair doubler disclosed herein.

[0010] Figure 8 It represents manufacturing Figure 4-6 Flowchart of the instance method of the instance repair doubler.

[0011] Fig. 9 It represents manufacturing Figure 7 A flowchart of another example method of an example repair doubler.

[0012] Generally, throughout the drawings and the accompanying written description, the same reference numerals will be used to refer to the same or similar parts. The drawings are not necessarily drawn to scale. Instead, the thickness of the layers or regions in the drawings may be exaggerated. Although the layers and regions shown in the drawings have clear lines and boundaries, some or all of these lines and / or boundaries may be idealized. In reality, the boundaries and / or lines may not be observable, blended, and / or irregular.

[0013] As used herein, the term "above" describes the relationship of two parts relative to the earth, unless otherwise specified. A first part is above a second part if the second part has at least one part between the earth and the first part. Likewise, as used herein, a first part is "below" a second part when the first part is closer to the earth than the second part. As described above, a first part can be above or below a second part with one or more of the following: having other parts in between, having no other parts in between, the first part and the second part in contact, or the first part and the second part not in direct contact with each other.

[0014] As used in this patent, describing any part (such as a layer, film, region, area or plate) as being on another part in any manner (such as positioned on, located on, arranged on or formed on, etc.) means that the referenced part is in contact with the other part, or that the referenced part is located above the other part with one or more intermediate parts positioned therebetween.

[0015] As used herein, connection references (such as attached, coupled, connected, and joined) may include intermediate members between the elements to which the connection reference refers and / or relative movement between such elements unless otherwise specified. Thus, connection references do not necessarily infer that two elements are directly connected and / or are in fixed relation to each other. As used herein, stating that any part is "in contact with" another part is defined to mean that there are no intermediate parts between the two parts.

[0016] Unless otherwise specifically stated, descriptors used herein, such as "first," "second," "third," etc., do not imply or otherwise indicate any priority meaning, physical order, arrangement in a list, and / or ordering in any manner, but are merely labels and / or arbitrary names to distinguish elements to facilitate understanding of the disclosed examples. In some instances, the descriptor "first" may be used to refer to an element in the detailed description, while in the claims, the same element may be referred to by different descriptors, such as "second" or "third." In such cases, it should be understood that these descriptors are only used to clearly identify these elements in the context of the discussion (e.g., in the claims), which elements may, for example, otherwise share the same name.

[0017] As used herein, "approximately," "substantially," and "approximately" modify their subject matter / values ​​to account for possible variations that exist in real-world applications. For example, "approximately," "substantially," and "approximately" may modify dimensions that may not be exact due to manufacturing tolerances and / or other real-world imperfections that would be understood by one of ordinary skill in the art. For example, "approximately" and "approximately" may indicate that the dimensions may be within a tolerance range of + / - 10%, unless otherwise noted in the description below. For example, substantially smooth may mean perfectly smooth, or, while departing from perfectly smooth, provides a smooth surface that has the characteristics of an almost perfectly smooth surface, without certain non-smooth or rough portions. For example, substantially complementary as used herein means that one shape matches another shape perfectly, or matches almost perfectly, but with some imperfections. DETAILED DESCRIPTION

[0018] The construction of composite wing sections, wing leading edges, winglets, wingtips and / or other aerofoil structures (such as composite aerofoil structures) varies from truss structure arrangements to monocoque shell structures and semi-monocoque shell structures. Monocoque and semi-monocoque structures are structural skins that withstand tension and compression. These monocoque and semi-monocoque structures may be damaged by impacts caused by ground support equipment and / or bird strikes during flight. As used herein, a monocoque structure is such a structural system in which the load is supported by the outer skin of the object. As used herein, a semi-monocoque structure refers to a load-bearing shell structure similar to a monocoque structure, but at least some of its strength comes from traditional reinforcement structures, including, for example, spars, ribs, stringers, longitudinal beams, frames and / or other structural components.

[0019] Damage to monocoque and / or semi-monocoque structures can compromise structural integrity and / or affect the aerodynamic properties of the structure (e.g., an airfoil), which can result in flutter and / or reduce aircraft efficiency (e.g., increased drag, which results in higher fuel consumption). In some cases, damage to the structure makes parts of the aircraft vulnerable to damage from water and / or debris. Therefore, there is a need to quickly repair monocoque structures so that the aircraft can operate in accordance with aviation standards. However, known techniques for repairing monocoque and / or semi-monocoque structures are very time consuming and typically require the use of mechanical fasteners and / or metal forming tools. For example, some repairs may take several days, during which time the aircraft is inoperable or unusable. In addition, only certain hubs or airports provide the tools required for repair and / or inspection.

[0020] The examples described herein allow for quick and easy repair of winglets, wingtips, and / or other airfoil structures without the use of metal forming tools and / or mechanical fasteners (e.g., rivets, screws, etc.). The example methods and apparatus disclosed herein allow for repairs to be made to aircraft structures, enabling the aircraft to operate and / or deferring inspections until the aircraft can be flown to a hub or airport with available tools for permanent repairs and / or inspections. The example methods and apparatus described herein can provide temporary repairs to aircraft structures (e.g., monocoque and semi-monocoque shell structures, airfoils, etc.) until a more durable and permanent repair can be made to the structure. In some examples, the methods and apparatus disclosed herein can defer permanent repairs to an aircraft for at least six months, enabling the aircraft to continue normal operations (e.g., flying) without having to retire the aircraft.

[0021] Figure 1 1 is a perspective view of an example aircraft 100 having an example airfoil structure 101 that can be repaired according to the teachings of the present disclosure. The airfoil structure 101 of the illustrated example can include various types of airfoils, wing structures, monocoque structures, and / or semi-monocoque structures of the aircraft 100. For example, the airfoil structure 101 constructed of composite materials can include, but is not limited to, a wing leading edge 102, a horizontal stabilizer leading edge 104, an elevator 106, a vertical stabilizer leading edge 108, a rudder 110, a flap 112, an aileron 114, a slat 118, a winglet 120, and / or any other suitable airfoil, monocoque structure, and / or semi-monocoque structure. In the depicted example, the wing 102 includes the winglet 120.

[0022] Aircraft 100 is an example aircraft in which the doubler repair disclosed herein may be implemented according to an illustrative embodiment. Aircraft 100 in the illustrated example is a commercial passenger aircraft. However, the example methods and apparatus disclosed herein are not limited to Figure 1 1. Example aircraft 100. In some examples, aircraft 100 may be a military aircraft, a rotorcraft, a helicopter, an unmanned aerial vehicle, and / or any other suitable aircraft or craft.

[0023] Figure 2 Illustrated Figure 1The winglet 120 of the example aircraft 100. The winglet 120 in the example shown is an integral bifurcated winglet. For example, the winglet 120 is a part of the wing 102 and is made of a composite material. The winglet 120 of the example shown has a plurality of blades. The blades of the example shown are arranged at an angle relative to each other. As depicted, the bifurcated winglet 120 of the example shown has a first or upper blade 202 arranged at an angle relative to a second or lower blade 204. In some examples, the components in the winglet 120 have been co-cured to form a single part. Therefore, fasteners or other components are not required to connect a part of the winglet 120 (such as the upper blade 202) to another part of the winglet 120 (such as the lower blade 204). In this example shown, the winglet 120 has a smooth surface. The winglet 120 is configured to produce natural laminar flow.

[0024] As depicted, the winglet 120 includes an upper blade 202, a lower blade 204, and a root region 206. In this illustrated example, the length of the upper blade 202 is greater than the length of the lower blade 204. In some illustrated examples, the upper blade 202 and the lower blade 204 may be the same length. As shown, the upper blade 202 includes a leading edge 208 and a trailing edge 210, and the lower blade 204 includes a leading edge 212 and a trailing edge 214. The upper blade 202 has an outer side or outer skin 216, an inner side or inner skin 218, and a tip 220. In a similar manner, the lower blade 204 has an upper skin 222 (e.g., an upper surface), a lower skin 224 (e.g., a lower surface), and a tip 226. The lower blade 204 may be a monocoque structure or a semi-monocoque structure.

[0025] Figure 3 yes Figure 1 and Figure 2 1 is a perspective view of the lower blade 204 of the example winglet 120 having a damaged area 300 (e.g., a cutout). In this example, the damaged area 300 is located on the leading edge 212 of the lower blade 204. Since the outer portion 302 of the lower blade 204 is located below the wing 102 relative to the ground ( Figure 1 ), so the lower blade 204 may be susceptible to impact damage (e.g., damage caused by airport equipment or vehicles). Figure 3, a damaged area 300 is trimmed to remove damaged material from the lower blade 204 that may interfere with repairing the winglet 120. The damaged area 300 is a cut in the lower blade 204 or material that has been removed from the lower blade 204. The damaged area 300 of the illustrated example has a length L and a depth D. In this example, the length L is approximately 5.5 inches and the depth D is approximately 2.5 inches. However, in other examples, the length L may be approximately between 0.5 inches and 12 inches, and the depth D may be approximately between 0.5 inches and 6 inches. In some examples, the length L and / or the depth D may be any other suitable dimensions. In some examples, the damaged area 300 to be repaired may be along another portion of the winglet 120 (e.g., located within the outer two-thirds of the outer portion 302 of the lower blade 204) and / or Figure 1 any other airfoil structure 101 positioning.

[0026] Figure 4 yes Figure 1-3 A perspective view of a lower blade 204 having a cover disclosed herein Figure 3 The example repair doubler 400 of the damaged area 300 in FIG. The repair doubler 400 of the example shown can seal or cover Figure 3 The repair doubler 400 disclosed herein allows for repairs to be performed at any location (e.g., anywhere in the world), such as an airport that is not equipped with special tools for such repairs. Typically, repairs to monocoque and / or semi-monocoque components require special tools, such as metal forming tools. In contrast, the examples disclosed herein do not require any special tools, and the repair doubler 400 can be hand-formed to meet the aerodynamic profile of the monocoque and / or semi-monocoque structure to which the repair doubler is incorporated.

[0027] like Figure 4 As shown in FIG. 4 , the repair doubler 400 includes a profile 402 (e.g., a shape or curve) that is substantially similar (e.g., complementary) to a profile 406 (e.g., a shape or curve) of the leading edge 212. In some examples, the profile 402 is formed by hand-forming a doubler plate 408 (e.g., a doubler plate 408) over the damaged area 300. Figure 3). In the illustrated example, the doubler plate 408 is a flexible sheet of material (e.g., a thin sheet of material or a metal sheet) that can be formed (e.g., manually formed) or bent to conform to the shape of a portion of the lower blade 204 (e.g., or other airfoil structure). In some examples, the profile 402 is achieved by manually forming two sheets of material connected together via an adhesive or sealant (e.g., near the leading edge 212). In other examples, the doubler plate 408 is a single piece. In some examples, a tool is used to form the single piece into a contour shape, such as the profile 406. In some examples, the adhesive includes a paste, an adhesive and / or a sealant, any combination thereof, and / or any other material. In the illustrated example, the doubler plate 408 is located on the upper skin 222 and the lower skin 224 and is wrapped around the leading edge 212 of the lower blade 204.

[0028] Figure 5 is the lower blade 204 and Figure 4 Another perspective view of the example repair doubler 400. Figure 5 As shown in FIG. 1 , a doubler plate 408 (eg, a sheet of material) may be positioned on or around the damaged area 300 ( Figure 3 ). For example, the first portion 501 of the repair doubler 400 and / or doubler plate 408 of the illustrated example is located on the upper skin 222, the second portion 503 is located on the lower skin 224, and the third portion 505 is located on or around the leading edge 212 of the lower blade 204. Therefore, the repair doubler 400 and / or doubler plate 408 of the illustrated example has a curved or arcuate curve that conforms to or is complementary to the shape of the upper skin 222, the lower skin 224, and the leading edge 212. Therefore, the shape of the doubler plate 408 is at least similar to a portion of the airfoil shape. The repair doubler 400 and / or doubler plate 408 of the illustrated example has a substantially smooth curved or arcuate curve. Specifically, the repair doubler 400 and / or doubler plate 408 of the illustrated example has a C-shaped curve. The doubler plate 408 (eg, a sheet of material) of the illustrated example is bonded and / or attached to the skin 502 of the lower blade 204 via a paste, adhesive, and / or sealant.

[0029] The doubler plate 408 is formed by hand (e.g., without using a forming tool) to provide a profile 402 that is substantially complementary to the profile 406 of the leading edge 212. For example, the doubler plate 408 may initially have a flat square or rectangular shape. The doubler plate 408 is bent or formed by the operator's hand over a portion of the leading edge 212 to conform the doubler plate 408 to a shape substantially similar to the shape of the leading edge 212. In order to enable the doubler plate 408 to conform to the profile 402, the doubler plate 408 has a thickness T. In some examples, the thickness T of the doubler plate 408 is in a range between approximately 0.040 inches and 0.080 inches. In some examples, the thickness T is approximately 0.063 inches. In some examples, the thickness T of the doubler plate 408 may be less than 0.04 inches (e.g., 0.01 inches). The doubler plate 408 in the illustrated example is substantially lightweight and therefore does not add significant weight to the aircraft. Therefore, the doubler plate 408 has a negligible impact on fuel efficiency and / or weight.

[0030] The doubler plate 408 in the illustrated example is a flexible sheet of material. For example, the doubler plate 408 can be a metal sheet. In the illustrated example, the doubler plate 408 is a single or uniform sheet of metal. In other examples, the doubler plate 408 can be a flexible plastic (e.g., vinyl), a flexible wood, a flexible metal, and / or any other material that can be bent or formed to conform to the airfoil structure. In some examples, the doubler plate 408 can include aluminum (e.g., 7075-T6 clad aluminum sheet and / or bare aluminum sheet), galvanized steel, sheet metal, corrosion resistant steel (CRES), titanium, thermoplastics, pre-cured composites, alloys, and / or any other material or alloy.

[0031] like Figure 5 As shown, the doubler plate 408 covers the damaged area 300 and overlaps the skin 502 adjacent to the damaged area 300. Since the doubler plate 408 is shaped to conform to the shape of the leading edge 212 (e.g., the airfoil shape), the doubler plate 408 forms a portion of the outer surface or skin (e.g., the skin 502) of the lower blade 204. In other words, the edge or perimeter 508 (e.g., the end) of the doubler plate 408 engages (e.g., directly engages) with the winglet 120 (e.g., the skin). For example, a perimeter 508 of a first portion 501 of the doubler panel 408 engages or overlaps the upper skin 222 (e.g., adjacent to the damaged area 300), a perimeter 508 of a second portion 503 of the doubler panel 408 engages or overlaps the lower skin 224 (e.g., adjacent to the damaged area 300), and a perimeter 508 of a third portion 505 of the doubler panel 408 engages or overlaps the leading edge 212 (e.g., adjacent to the damaged area 300).

[0032] Tape or seal (e.g. Figure 6604) (e.g., a layer of tape) is positioned at least partially along a portion of an interface 506 between a perimeter 508 of the doubler panel 408 and a perimeter or edge 510 (e.g., a cutout) of the skin 502 adjacent the damaged area 300. In the illustrated example, the doubler panel 408 overlaps the skin 502 (e.g., the edge 510 of the damaged area 300) with an overlap thickness X. In some examples, the overlap thickness X may be approximately between 1.5 inches and 3 inches (e.g., 2 inches). In some examples, the overlap thickness X may be any other suitable thickness greater than 1.5 inches. In some examples, two or more layers of tape may be applied.

[0033] Figure 6 Explained Figure 4 204 and an example cross-sectional view of an example lower blade 204 and an example repair doubler 400. The repair doubler 400 is located above the damaged area 300 and is bonded or attached to the skin 502 near the leading edge 212. The repair doubler 400 is bonded and / or attached to the skin 502 by an adhesive 600. In some examples, the adhesive 600 is located between the doubler panel 408 and the skin 502 at the leading edge 212. Figure 6 As shown in FIG. 4 , the doubler plate 408 overlaps the leading edge 212 of the lower blade 204 adjacent to an edge 602 (e.g., a point) of the damaged area 300 adjacent to the leading edge 212. In some examples, the adhesive 600 includes a paste, an adhesive, a sealant, a structural adhesive, etc. The adhesive 600 is added to the bottom or back side 610 of the doubler plate 408 and / or the surface 612 of the skin 502. In some examples, the adhesive 600 is added to at least a portion of the perimeter 508 of the doubler plate 408 or the perimeter 508 of the skin 502 adjacent to the damaged area 300 or outlining the damaged area 300. The example repair doubler 400 further includes a tape layer 604 located over at least a portion of the interface 506 of the doubler plate 408 and the skin 502. In some examples, the tape 604 overlaps the edge 608 of the skin 502 by a length Y (e.g., an overlap of approximately 2 inches). In other examples, the tape 604 covers the entire perimeter 508 ( Figure 5 ). In other examples, the tape 604 covers the entire doubler plate 408 (e.g., the entire surface area or exposed surface of the doubler plate 408). In some examples, the tape layer 604 can be aluminum pressure sensitive tape, aircraft speed tape (e.g., aluminum speed tape), foil tape, etc. Figure 6 As shown in , the doubler plate 408 is a single or unitary plate. In other examples, the doubler plate 408 includes multiple pieces bonded together by an adhesive.

[0034] Figure 7 is a cross-sectional view of another example repair doubler 700 disclosed herein. Figure 7 Many components of the example repair doubler 700 are combined with the above Figure 4-6 The components of the repair doubler 400 described are substantially similar or identical. Therefore, these components will not be described in detail below. Instead, the interested reader is referred to the corresponding description above for a complete written description of the structure and operation of these components. To facilitate this process, Figure 7 A similar structure in would use Figure 1-6 Similar or identical reference numbers in the

[0035] The repair doubler 700 of the illustrated example is bonded and / or attached to the skin 502 of the lower blade 204 by an adhesive 600. The repair doubler 700 of the illustrated example includes a doubler plate 702, a first tape layer 604, a second tape layer 704, and an adhesive 600. The doubler plate 702 of the illustrated example includes a first material sheet (such as a metal sheet) or a first doubler plate 706 and a second material sheet (such as a metal sheet) or a second doubler plate 708. Although the present example shows a first doubler plate 706 and a second doubler plate 708, the examples herein should not be limited to two doubler plates. In other examples, the doubler plate 702 may include a plurality of doubler plates or material sheets (e.g., more than two sheets, three doubler plates or material sheets, six doubler plates or material sheets, etc.). In some examples, the first doubler plate 706 and the second doubler plate 708 are bonded and / or attached by an adhesive 709 (e.g., structural adhesive, sealant, paste, etc.). In some examples, the adhesive 709 is added to the first butt end 710 of the first doubler plate 706 and / or the second butt end 712 of the second doubler plate 708. The first and second doubler plates 706, 708 are bonded together and positioned at the leading edge 212 forming the airfoil shape. In some examples, a tape layer (e.g., tape 604, 704) can be applied to the seam formed between the butt ends 710, 712. In some examples, in addition to or instead of the adhesive 709, the tape can also be applied to the seam. The use of the first doubler plate 706 and the second doubler plate 708 (e.g., multiple doubler plates) helps to shape the doubler plate 702 into the shape of the lower blade 204. For example, the first doubler panel 706 is formed or bent along the portion of the upper skin 222 of the lower blade 204 and the leading edge 212 adjacent to the damaged area 300. Similarly, the second doubler panel 708 is formed or bent along the portion of the lower skin 224 of the lower blade 204 and the leading edge 212 adjacent to the damaged area 300. The first doubler panel 706 conforms to the first portion of the leading edge 212, and the second doubler panel 708 conforms to the second portion of the leading edge 212. The first doubler panel 706 and the second doubler panel 708 can be joined at their respective butt ends 710, 712 to define the doubler panel 702, thereby covering the damaged area 300 of the leading edge 212 of the lower blade 204.

[0036] The sizes and shapes of the first and second doubler plates 706, 708 may be different. In some examples, the shapes of the first and second doubler plates 706, 708 are rectangular or flat and are bent during the molding process of the first and second doubler plates 706, 708. In other examples, the shapes of the first and second doubler plates 706, 708 are polygonal. The first and second doubler plates 706, 708 may be made of a variety of materials, including but not limited to aluminum (e.g., 7075-T6 clad aluminum sheet and / or bare aluminum sheet), galvanized steel, sheet metal, corrosion resistant steel (CRES), titanium, thermoplastics, pre-cured composite materials, and / or any other material that can conform to the shape of the leading edge 212 of the airfoil. The first and second doubler plates 706, 708 may be constructed of the same or different materials.

[0037] The example repair doubler 700 further includes a first tape layer 604 positioned over at least a portion of the interface 506 of the doubler panel 702 and the edge 608 of the skin 502. In the illustrated example, a second tape layer 704 is positioned over at least a portion of the interface 506 of the doubler panel 702 and the edge 608 of the skin 502. In some examples, the first tape layer 604 and the second tape layer 704 may be aluminum pressure sensitive tape, high speed tape, foil tape, aircraft high speed tape, etc. In other examples, the first tape layer 604 and the second tape layer 704 may be the same or different materials. Although Figure 7 Two tape layers 604, 704 are shown, but examples herein are not limited thereto. In some examples, the repair doubler 700 includes more than two tape layers 604, 704 (e.g., three tape layers, six tape layers, etc.). The second tape layer 704 can be positioned in an offset or overlapping relationship with the first tape layer 604. For example, the second tape layer 704 can overlap the first tape layer 604 by a distance of approximately between 1 inch and 2 inches (e.g., 1.5 inches).

[0038] Figure 8 It means to fasten the parts together without using mechanical fasteners (such as screws, rivets, etc.) and without any special tools. Figure 4-7 The example repair doubler 400 in FIG. 8 provides a flow chart of an example method 800 for repairing a damaged region 300. Although the example method is based on Figure 8 The flowchart shown is described, but many other methods may also be used optionally. For example, the execution order of the blocks may be changed, and / or some blocks may be combined, divided, rearranged, omitted, eliminated and / or executed in any other manner.

[0039] Figure 8 The example method 800 of FIG. 8 begins at block 802 where a sheet of material is obtained that has a profile substantially complementary to a profile of an airfoil. In some examples, the airfoil corresponds to Figure 2-7 In some examples, the material sheet corresponds to the leading edge 212 or the trailing edge 210, 214. Figure 4-7 Doubler plate 408. In some examples, the profile of the sheet of material is obtained by manually shaping the sheet of material over the airfoil. For example, doubler plate 408 may initially have a substantially flat square or rectangular shape. In some cases, doubler plate 408 is manually shaped over leading edge 212 adjacent to damaged area 300 to change the shape of doubler plate 408 from a substantially flat square or rectangular shape to a profile substantially similar to the profile of leading edge 212. After doubler plate 408 is shaped with the reverse side of the airfoil or leading edge 212, the curved doubler plate 408 slides and / or moves over damaged area 300 of leading edge 212 to cover or overlap damaged area 300. In some examples, doubler plate 408 may be pre-shaped or may already have an airfoil shape. This configuration eliminates the need for an operator to shape doubler plate 408. As used herein, substantially complementary means that the sheet of material has a similar profile (eg, radius of curvature within plus or minus 10%) to the leading edge of an airfoil, wing or blade (eg, vertical stabilizer, horizontal stabilizer, winglet, etc.) In some examples, a tool is used to form the contoured shape.

[0040] At block 804, an adhesive is applied to at least one of the back side of the sheet of material or the skin of the airfoil. In some examples, the adhesive corresponds to Figure 6 Adhesive 600. Figure 4-6 , the adhesive is applied to the back side 610 of the doubler plate 408 and / or the surface 612 of the skin 502. In some examples, the adhesive is applied to at least a portion of the perimeter of the back side 610 of the doubler plate 408 and / or the surface 612 of the skin 502 that is adjacent to or around the perimeter of the damaged area 300 (e.g., the cutout). In some examples, the adhesive is applied to at least the back side 610 of the doubler plate 408 and / or the entire perimeter of the surface 612 of the skin 502 adjacent to the damaged area 300.

[0041] At block 806 , the piece of material is bonded to the airfoil. In other words, the piece of material is bonded to the leading edge above the damaged area 300 (eg, to cover the damaged area 300 ).

[0042] At block 808, tape is applied and / or bonded to at least a portion of the sheet material and the skin. Figure 5-7 , applying tape 604 to doubler panel 408 and skin 502. Specifically, tape 604 is applied along at least a portion of perimeter 508 of doubler panel 408. After completing block 808, Figure 8The example method 800 ends and the repair doubler is completed, which allows the aircraft to operate until a permanent repair can be completed. In some examples, the repair doubler disclosed herein can provide a temporary repair that enables the aircraft to operate for six months or 250 cycles, whichever comes first.

[0043] Fig. 9 It represents the manufacturing process without the use of fasteners and without the need for any special tools. Figure 7 Another flow chart of another example method 900 of the example repair doubler 700 of the present invention. Although the present example method is to refer to Fig. 9 The flowchart shown in the embodiment is described, but many other methods may also be used optionally. For example, the execution order of the blocks may be changed, and / or some blocks may be combined, divided, rearranged, omitted, eliminated and / or executed in any other manner.

[0044] Fig. 9 The example method 900 begins at block 902 where a first metal sheet is bent around a first portion of an airfoil (eg, a leading edge of a wing) that is adjacent to a damaged portion of the airfoil. Figure 7 The first doubler panel 706 is bent or formed along a first portion of the leading edge 212 of the lower blade 204. For example, the first doubler panel 706 is bent over a portion of the upper skin 222 and a portion of the leading edge 212 of the lower blade 204.

[0045] At block 904, the second metal sheet is bent around a second portion of the airfoil, the second portion being adjacent to the damaged portion of the airfoil. Figure 7 , the second doubler plate 708 is bent or formed along a second portion of the leading edge 212 of the lower blade 204. For example, the second doubler plate 706 is bent over a portion of the lower skin 224 of the lower blade 204 and a portion of the leading edge 212. In some instances, the first and second metal sheets are bent by hand around the first and second portions of the leading edge, respectively. One aspect of bending the first and second metal sheets (e.g., doubler plates 706, 708) by hand is that the process does not require any special tools, so the repair can be completed at a remote location. However, in some cases, the first and second metal sheets can be formed on a tool of complementary (same as the leading edge) shape. In some instances, the first and second metal sheets can be preformed by complementary tools. The first metal sheet and the second metal sheet conform to the shape of the airfoil.

[0046] At block 906, adhesive is added to at least one of a perimeter of the first metal sheet or a perimeter of the airfoil adjacent to the damaged portion to be covered by the first metal sheet. Figure 7, adhesive 600 is applied to the rear side or surface adjacent to the peripheral edge of the first doubler panel 706 and / or to the skin 502 of the leading edge 212 adjacent to the peripheral edge of the damaged area 300 to be covered by the first doubler panel 706.

[0047] At block 908, adhesive is added to at least one of a perimeter of the second metal sheet or a perimeter of the airfoil to be adjacent to the damaged portion covered by the second metal sheet. Figure 7 , adhesive 600 is applied to the rear side or surface adjacent to the peripheral edge of the second doubler panel 708 and / or to the skin 502 of the leading edge 212 adjacent to the peripheral edge of the damaged area 300 to be covered by the second doubler panel 708.

[0048] At block 910, an adhesive is added to at least the first butt end of the first metal sheet or the second butt end of the second metal sheet. Figure 7 , adhesive 709 is added to the butt ends 710, 712 of the first doubler plate 706 and the second doubler plate 708, respectively, to form the doubler plate 702. However, in some examples, adhesive 709 is only added to the butt ends 710 or the butt ends 712. The example method 900 includes a first metal sheet and a second metal sheet, but the example should not be limited to this. In some examples, the method 900 can include a doubler plate having more than two sheets of material or metal (e.g., three sheets, four sheets, etc.), which can be joined together as a single doubler plate.

[0049] At block 912, the first metal sheet and the second metal sheet are attached to the airfoil. In some examples, the doubler plate 702 is fixed, bonded or attached to the skin 502 by an adhesive 600. The doubler plate 702 is located above the damaged area 300 to cover the damaged area 300. In other words, the doubler plate 702 forms the outer surface of the airfoil and / or the leading edge 212 of the lower blade 204. The butt ends 710, 712 are meshed or combined together to form the doubler plate 702. In some examples, the first metal sheet is attached to the airfoil before the second metal sheet. In some examples, the second metal sheet is attached to the airfoil before the first metal sheet. In some examples, the first metal sheet is attached to the second metal sheet to form the doubler plate, and then the first metal sheet and the second metal sheet are attached to the airfoil together or simultaneously.

[0050] At block 914, the tape is bonded to at least a portion of the peripheral edge of the doubler plate and the airfoil. Figure 7 , applying the first tape layer 604 to the doubler plate 702 and a portion of the skin 502 adjacent to the perimeter edge of the doubler plate 702. Applying the second tape layer 704 to the first tape layer 604 and / or the skin 502. After completing block 912, Fig. 9The example method 900 in ends and completes the repair doubler, which allows the aircraft to operate normally until a permanent repair can be completed. In some examples, the repair doubler enables the aircraft to operate for six months or 250 cycles, whichever comes first.

[0051] Although each of the example repair doublers disclosed above (e.g., repair doublers 400, 700) has certain features, it should be understood that the specific features of an example are not necessarily exclusive to that example. Instead, any feature described above and / or depicted in the accompanying drawings can be used in conjunction with any example to supplement or replace any other features of those examples. Features of one example are not mutually exclusive with features of another example. On the contrary, the scope of the present disclosure includes any combination of any features.

[0052] As used herein, "include" and "comprising" (and all forms and tenses thereof) are open-ended terms. Thus, whenever a claim uses any form of "include" or "comprising" (e.g., includes, comprises, contains, has, etc.) as a preamble or in any type of claim statement, it should be understood that additional elements, terms, etc. may be present without exceeding the scope of the corresponding claim or statement. As used herein, when the phrase "at least" is used as a transitional term, for example, in the preamble of a claim, it is open-ended in the same manner as the terms "include" and "comprising" are open-ended. For example, when the term "and / or" is used in the form of, for example, A, B, and / or C, it refers to any combination or subset of A, B, and C, such as (1) A alone, (2) B alone, (3) C alone, (4) A and B, (5) A and C, (6) B and C, or (7) A and B and C. As used herein, in the context of describing structures, components, items, objects, and / or things, the phrase “at least one of A and B” refers to implementations that include any of the following: (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. Similarly, as used herein, in the context of describing structures, components, items, objects, and / or things, the phrase “at least one of A or B” is intended to include implementations that include any of the following: (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. As used herein, in the context of describing the performance or execution of processes, instructions, actions, activities, and / or steps, the phrase “at least one of A and B” is intended to include implementations that include any of the following: (1) at least one A, (2) at least one B, or (3) at least one A and at least one B. Similarly, as used herein, in the context of describing the performance or execution of a process, instruction, action, activity, and / or step, the phrase "at least one of A or B" is intended to include implementations of any of the following: (1) at least one A, (2) at least one B, or (3) at least one A and at least one B.

[0053] As used herein, singular references (such as "a", "an", "first", "second", etc.) do not exclude the plurality. As used herein, the term "a" or "an" object refers to one or more of the object. The terms "a" (or "an"), "one or more" and "at least one" may be used interchangeably herein. In addition, although listed separately, multiple means, elements or actions may be implemented by, for example, the same entity or object. In addition, although individual features may be included in different examples or claims, these features may also be possible to combine, and inclusion in different examples or claims does not mean that the combination of features is not feasible and / or disadvantageous.

[0054] From the foregoing, it can be appreciated that example systems, devices, articles of manufacture, and methods have been disclosed that produce repairs for monocoque components that can be quickly completed at a remote location. The examples disclosed herein do not require fasteners or special tools. In addition, the example repairs disclosed herein are lightweight and do not require removal of the winglets. The examples disclosed herein use standard repair materials that allow for a quick repair turnaround. The disclosed systems, devices, articles of manufacture, and methods can save time and cost in repairing damaged monocoque and / or semi-monocoque components described herein. The disclosed systems, devices, articles of manufacture, and methods are accordingly directed to improvements in the operation of one or more machines (such as computers or other electronic and / or mechanical devices).

[0055] Disclosed herein are example methods, devices, systems, and articles of manufacture for repairing monocoque or semi-monocoque structures. Further examples and combinations thereof include the following:

[0056] Embodiment 1 includes an apparatus for repairing a semi-monocoque wing, comprising a doubler panel configured to be bonded to a skin of the semi-monocoque wing by a first adhesive, the doubler panel having a profile substantially complementary to a profile of a leading edge of the semi-monocoque wing, and a tape layer positioned at least partially along at least a portion of an interface between an edge of the doubler panel and a leading edge of the skin.

[0057] Embodiment 2 includes a device as defined in embodiment 1, wherein the doubler plate includes a first doubler plate attached to a second doubler plate by a second adhesive.

[0058] Embodiment 3 includes the apparatus defined in any of embodiments 1-2, wherein the tape overlaps at least one of an edge of the doubler panel or a leading edge of the skin by a range of 1.5 inches to 3 inches.

[0059] Embodiment 4 includes a device as defined in any of embodiments 1-3, wherein the first adhesive comprises at least one of a paste, an adhesive, or a sealant.

[0060] Embodiment 5 includes the device defined in any of embodiments 1-4, wherein the doubler plate has a thickness between approximately 0.040 inches and 0.080 inches.

[0061] Embodiment 6 includes the device defined in any of embodiments 1-5, wherein the doubler plate comprises aluminum.

[0062] Embodiment 7 includes the apparatus defined in any of embodiments 1-6, wherein the doubler plate comprises galvanized steel.

[0063] Embodiment 8 includes the device defined in any one of embodiments 1-7, wherein the tape is a high-speed tape.

[0064] Embodiment 9 includes the apparatus defined in any one of embodiments 1-8, wherein the wing is a winglet, and the leading edge is located on a lower blade of the winglet.

[0065] Embodiment 10 includes the apparatus defined in any one of embodiments 1-9, wherein the wing is a vertical stabilizer and the leading edge is on the vertical stabilizer.

[0066] Embodiment 11 includes a method for repairing a semi-monocoque wing, the method comprising obtaining a sheet of material having a profile substantially complementary to a profile of a leading edge of the semi-monocoque wing; applying an adhesive to at least one of a rear side of the sheet of material or a skin of the semi-monocoque wing; bonding the sheet of material to a portion of the leading edge of the semi-monocoque wing to bond the sheet of material and the skin by the adhesive; and applying tape to at least a portion of the sheet of material and the skin.

[0067] Embodiment 12 comprises a method as defined in embodiment 11, wherein bonding of the sheet of material comprises positioning the sheet of material over a damaged portion of the leading edge of the wing.

[0068] Embodiment 13 includes a method as defined in any of embodiments 11-12, wherein obtaining the sheet of material includes bending the sheet of material over a portion of the leading edge of the wing adjacent the damaged portion such that the shape of the sheet of material is substantially complementary to the shape of the leading edge.

[0069] Embodiment 14 includes a method as defined in any of embodiments 11-13, wherein the bonding of the tape includes applying the tape along the entire interface between the edge of the sheet of material and the leading edge of the skin.

[0070] Embodiment 15 includes a method as defined in any of embodiments 11-14, wherein the material sheet includes a first material sheet attached to a second material sheet by a second adhesive.

[0071] Embodiment 16 includes a method as defined in any of embodiments 11-15, wherein the sheet of material includes aluminum.

[0072] Embodiment 17 includes a method as defined in any of embodiments 11-16, wherein the tape overlaps the skin in a range of 1.5 inches to 3 inches.

[0073] Embodiment 18 includes a method for repairing a semi-monocoque wing, comprising bending a first metal sheet around a first portion of a leading edge of the wing, the first portion being adjacent to a damaged portion of the leading edge; bending a second metal sheet around a second portion of a leading edge of the wing, the second portion being adjacent to the damaged portion of the leading edge, the second portion being different from the first portion; adding an adhesive to at least one of the butted ends of the first metal sheet and the second metal sheet to bond the first metal sheet and the second metal sheet to form a doubler plate, wherein when the first metal sheet is bonded to the second metal sheet, the first metal sheet and the second metal sheet form an airfoil shape that is complementary to the airfoil shape of the leading edge of the wing; applying an adhesive to at least one of a periphery of the doubler plate or a periphery of a wing skin adjacent to the damaged portion; attaching the doubler plate to the wing skin; and bonding a tape to a periphery edge of the doubler plate and to at least a portion of the skin adjacent to the periphery edge of the doubler plate.

[0074] Embodiment 19 includes the method as defined in Embodiment 18, wherein the attaching of the tape comprises applying the tape along the entire perimeter of the doubler panel and the skin of the wing adjacent to the damaged portion.

[0075] Embodiment 20 includes the method as defined in any of Embodiments 18-19, wherein the tape overlaps the skin adjacent to the perimeter of the doubler panel by a range of 1.5 inches to 3 inches.

[0076] The attached claims are incorporated into the detailed description by this reference. Although certain example systems, devices, articles of manufacture, and methods are disclosed herein, the coverage of this patent is not limited thereto. On the contrary, this patent covers all systems, devices, articles of manufacture, and methods within the scope of the claims of this patent.

Claims

1. A device for repairing a semi-monocoque wing (102, 120), comprising: a doubler panel (408) configured to be bonded to the skin (222) of the semi-monocoque wing via a first adhesive (600), the doubler panel having a profile (402) substantially complementary to a profile (406) of a leading edge (212) of the semi-monocoque wing; and A layer of tape (604) is positioned at least partially along at least a portion of an interface (506) between an edge (508) of the doubler panel and a leading edge of the skin.

2. The apparatus of claim 1, wherein the doubler plate comprises a first doubler plate (706) attached to a second doubler plate (708) by a second adhesive (709).

3. The apparatus of claim 1, wherein the tape overlaps at least one of an edge of the doubler panel or a leading edge of the skin by a range of 1.5 inches to 3 inches.

4. The device of claim 1, wherein the first adhesive comprises at least one of an adhesive, a paste, or a sealant.

5. The apparatus of claim 1, wherein the thickness (T) of the doubler plate is between approximately 0.040 inches and 0.080 inches.

6. The apparatus of claim 1 wherein the doubler plate comprises aluminum.

7. The apparatus of claim 1 wherein the doubler plate comprises galvanized steel.

8. The device of claim 1, wherein the tape is a high-speed tape.

9. The apparatus of claim 1, wherein the wing is a winglet (120) and the leading edge is located on a lower blade (204) of the winglet.

10. The apparatus of claim 1, wherein the wing is a vertical stabilizer and the leading edge is on the vertical stabilizer.

11. A method for repairing a semi-monocoque wing, comprising: obtaining a sheet of material (408, 402) having a profile substantially complementary to a profile (406) of a leading edge (212) of the semi-monocoque wing (102, 120); applying an adhesive (600, 804) to at least one of a rear side (610) of the sheet of material (408) or a skin (502) of the semi-monocoque wing; bonding the sheet of material over a portion (300, 806) of a leading edge (212) of the semi-monocoque wing to bond the sheet of material and the skin by adhesive; Adhesive tape is applied over the sheet of material and at least a portion of the skin (604, 808).

12. The method of claim 11, wherein bonding the sheet of material comprises positioning the sheet of material over a damaged portion (300) of the leading edge of the wing.

13. The method of claim 12, wherein obtaining the sheet of material comprises bending the sheet of material over a portion (212) of the leading edge of the wing adjacent the damaged portion to shape the sheet of material substantially complementary to the shape of the leading edge.

14. The method of claim 11, wherein the bonding of the tape comprises applying the tape along the entire interface between the edge of the sheet of material and the leading edge of the skin.

15. The method of claim 11, wherein the sheet of material comprises a first sheet of material (706) attached to a second sheet of material (708) by a second adhesive (709).

16. The method of claim 11, wherein the sheet of material comprises aluminum.

17. The method of claim 11, wherein the tape overlaps the skin in a range of 1.5 inches to 3 inches.

18. A method for repairing a semi-monocoque wing, comprising: bending a first metal sheet (706, 902) around a first portion of a leading edge (212) of a wing (102, 120), the first portion being adjacent to a damaged portion (300) of the leading edge; bending a second metal sheet (706, 904) around a second portion of the leading edge of the wing, the second portion being adjacent to the damaged portion of the leading edge, the second portion being different from the first portion; adding an adhesive (709, 910) to at least one of the butted ends of the first metal sheet and the second metal sheet to bond the first metal sheet and the second metal sheet to form a doubler plate, wherein when the first metal sheet and the second metal sheet are bonded, the first metal sheet and the second metal sheet form an airfoil shape complementary to the airfoil shape of the leading edge of the wing; applying adhesive (600) to at least one of a perimeter (508) of the doubler panel or a perimeter of the skin (502) of the wing adjacent the damaged portion; attaching the doubler panel to the skin of the wing; and Adhesive tape (604) is bonded to a peripheral edge (508) of the doubler plate and to at least a portion of the skin adjacent the peripheral edge of the doubler plate.

19. The method of claim 18, wherein the attaching of the tape comprises applying tape along the entire perimeter of the doubler panel and the skin of the wing adjacent the damaged portion.

20. The method of claim 18, wherein the tape overlaps the skin adjacent the perimeter of the doubler panel by a range of 1.5 inches to 3 inches.

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