Repair hat stringer

Abstract

The present disclosure provides a method of repairing a hat stringer. The method includes arranging the repair stringer in an installation location, the installation location being one of a plurality of possible installation locations along a cross-section of the hat stringer. In each of the plurality of possible installation locations, at least a portion of the interior profile of the repair stringer matches at least a portion of the profile of the interior cavity defined by the hat stringer. A cross-sectional area of the repair stringer as viewed in the first direction is smaller than a total cross-sectional area of the hat stringer as viewed in the first direction. The method further includes coupling the repair stringer with the stringer of the hat stringer at the installation location. A repair stringer and a repaired hat stringer are also provided.

Description

Technical Field

[0001] Aspects of the present disclosure relate to the repair of aircraft structural components, and more particularly, to the repair of hat stringers. Background Art

[0002] Aircraft structures must be able to withstand loads in a variety of different directions. For example, an aircraft wing must be able to withstand the aerodynamic loads imposed on the wing during flight. Such aerodynamic loads include bending loads that are accommodated by the wing skin and the internal wing structure. Bending loads are typically accommodated by stiffeners or stringers in the internal wing structure. Stringers are connected to the wing skin and extend generally along the interior of the wing in the span direction. Stringers can be arranged in a variety of different cross-sectional shapes and sizes, including hat-shaped sections. Hat-shaped stringers (or simply hat-shaped stringers) typically include a pair of webs that extend from the base of the stringer and are connected by a cap to surround the hat-shaped section.

[0003] In some cases, hat stringers may be damaged or otherwise require reinforcement, such as due to a collision event. Conventional techniques for repairing damaged hat stringers present certain challenges. Therefore, there is a need for one or more improved hat stringer repair techniques and / or repair stringers. Summary of the invention

[0004] In one aspect, the present disclosure provides a method for repairing a hat stringer. The method includes: arranging the repair stringer at an installation position, the installation position being one of a plurality of possible installation positions along a cross section of the hat stringer, and at each of the plurality of possible installation positions, at least a portion of an inner profile of the repair stringer matches at least a portion of a profile of an inner cavity defined by the hat stringer, and wherein a cross-sectional area of ​​the repair stringer viewed along a first direction is less than a total cross-sectional area of ​​the hat stringer viewed along the first direction. The method also includes coupling the repair stringer to a stringer of the hat stringer at the installation position.

[0005] In some other aspects in combination with any of the above or below exemplary methods, in each of a plurality of possible installation positions, the repair stringer has a web section extending parallel to a contoured web portion of the inner cavity.

[0006] In some other aspects in combination with any of the above or below exemplary methods, in each of a plurality of possible installation positions, the repair stringer has at least one section extending parallel to a cover portion of the inner cavity or a flange section of the stringer.

[0007] In some other aspects in combination with any of the above or below exemplary methods, the hat stringer defines a center plane that divides a first side and a second side of the hat stringer, and wherein the plurality of possible installation positions includes a first possible installation position and a second possible installation position, wherein the repair stringer is primarily positioned on the first side of the hat stringer and wherein the plurality of possible installation positions includes a first possible installation position and a second possible installation position, wherein the repair stringer is primarily positioned on the second side of the hat stringer.

[0008] In some other aspects in combination with any of the above or below exemplary methods, a repair stringer has a cover section, a flange section, and a web section, the web section extending between and connecting the cover section and the flange section, and wherein, when the repair stringer is arranged in an installed position, the cover section of the repair stringer extends parallel to the cover section of the stringer, the web section of the repair stringer extends parallel to the web section of the stringer, and the flange section of the repair stringer extends parallel to the flange section of the stringer.

[0009] In some other aspects in combination with any of the exemplary methods above or below, the repair stringer is a first repair stringer, and wherein the method further comprises arranging a second repair stringer in a mounting position along a cross-section of the hat stringer, the second repair stringer being shaped to have an interior profile that matches at least a portion of a profile of the inner cavity, and wherein a cap section of the second repair stringer and a cap section of the first repair stringer physically overlap each other and both extend parallel to the cap portion of the profile of the inner cavity.

[0010] In some other aspects in combination with any of the above or below exemplary methods, the first repair stringer has a web section that physically overlaps the first web section of the stringer and the second repair stringer has a web section that physically overlaps the second web section of the stringer.

[0011] In some other aspects in combination with any of the above or below exemplary methods, the second repair stringer has a flange section extending parallel to but spaced apart from the second flange section of the stringer, and wherein the method further comprises disposing one or more shims between the second flange section and the flange section of the second repair stringer.

[0012] In some other aspects in combination with any of the above or below exemplary methods, the second repair beam has a same cross-sectional shape as the first repair beam as viewed along the first direction.

[0013] In yet other aspects in combination with any of the above or below exemplary methods, the method further includes arranging a second repair stringer in an installation position along a cross section of the hat stringer, the second repair stringer being shaped to have an interior profile that matches at least a portion of a profile of the interior cavity. The method further includes arranging a third repair stringer in an installation position along the cross section of the hat stringer, the third repair stringer having a first web section, a cap section, and a second web section. The first web section is coupled to the repair stringer, the cap section is coupled to the stringer, and the second web section is coupled to the second repair stringer.

[0014] In some other aspects in combination with any of the above or below exemplary methods, the hat stringer defines a center plane that divides a first side and a second side of the hat stringer, and the plurality of possible installation positions includes at least four possible installation positions, and wherein the at least four possible installation positions include: at least two possible installation positions in which the repair stringer can be primarily positioned on the first side of the hat stringer; and at least two possible installation positions in which the repair stringer can be primarily positioned on the second side of the hat stringer.

[0015] In some other aspects in combination with any of the exemplary methods above or below, at least two possible installation positions in which the repair stringer can be primarily positioned on a first side of the hat stringer include a first installation position and a second installation position, and in the first installation position, a section of the repair stringer extends parallel to the first flange section of the stringer, and a section of the repair stringer extends parallel to the first web section of the stringer, and in the second installation position, a section of the repair stringer extends parallel to the cap section of the stringer, and a section of the repair stringer extends parallel to the first web section of the stringer.

[0016] In some other aspects in combination with any of the exemplary methods above or below, at least two possible installation positions in which the repair stringer is primarily positioned on the second side of the hat stringer include a first installation position and a second installation position, and in the first installation position, a section of the repair stringer extends parallel to the cap section of the stringer, and a section of the repair stringer extends parallel to the second web section of the stringer, and in the second installation position, a section of the repair stringer extends parallel to the second flange section of the stringer, and a section of the repair stringer extends parallel to the second web section of the stringer.

[0017] In some other aspects in combination with any of the exemplary methods above or below, the stringer includes a first flange section, a first web section, a cover section, a second web section, and a second flange section, and wherein a plurality of possible installation positions along a cross-section of the hat-type stringer include a first installation position, a second installation position, a third installation position, and a fourth installation position, and: in the first installation position, a section of the repair stringer extends parallel to the first flange section of the stringer, and a section of the repair stringer extends parallel to the first web section of the stringer, in the second installation position, a section of the repair stringer extends parallel to the cover section of the stringer, and a section of the repair stringer extends parallel to the first web section of the stringer, in the third installation position, a section of the repair stringer extends parallel to the cover section of the stringer, and a section of the repair stringer extends parallel to the second web section of the stringer, and in the fourth installation position, a section of the repair stringer extends parallel to the second flange section of the stringer, and a section of the repair stringer extends parallel to the second web section of the stringer.

[0018] In some other aspects in combination with any of the exemplary methods above or below, the repair stringer is a first repair stringer and the installation position is a first installation position, and wherein the method further comprises arranging a second repair stringer at a second installation position; arranging a third repair stringer at a third installation position; arranging a fourth repair stringer at a fourth installation position; and coupling the second repair stringer to the stringer at the second installation position, coupling the third repair stringer to the stringer at the third installation position, coupling the fourth repair stringer to the stringer at the fourth installation position, wherein in the first installation position the first repair stringer was coupled to the stringer.

[0019] In some other aspects in combination with any of the above or below exemplary methods, the first and second repair beams physically overlap each other, the second and third repair beams physically overlap each other, and the third and fourth repair beams physically overlap each other.

[0020] In some other aspects in combination with any of the above or below exemplary methods, the first repair beam, the second repair beam, the third repair beam, and the fourth repair beam all have the same cross-sectional shape as viewed along the first direction, and wherein the second repair beam is oriented to be vertically and horizontally flipped relative to the first repair beam, the third repair beam is oriented to be vertically flipped relative to the first repair beam, and the fourth repair beam is oriented to be horizontally flipped relative to the first repair beam.

[0021] In some other aspects in combination with any of the above or below exemplary methods, the repair stringer is a first repair stringer, and wherein the first repair stringer is arranged such that a section of the first repair stringer is positioned in or adjacent to a plane in which a missing section of the stringer was previously positioned, and wherein the method further comprises arranging a second repair stringer and a third repair stringer such that a section of the second repair stringer and a section of the third repair stringer sandwich a section of the first repair stringer positioned in or adjacent to the plane; arranging a fourth repair stringer such that a section of the fourth repair stringer and the first repair stringer sandwich the second repair stringer; and coupling the first repair stringer, the second repair stringer, the third repair stringer, and the fourth repair stringer to each other and to the stringer.

[0022] In another aspect, a method is provided. The method includes: arranging a first repair stringer along a cross section of a hat stringer, the interior profile of the first repair stringer matching at least a portion of a profile of an interior cavity defined by the hat stringer; arranging a second repair stringer along the cross section of the hat stringer, the interior profile of the second repair stringer matching at least a portion of a profile of the interior cavity, the first repair stringer and the second repair stringer being arranged such that a section of the second repair stringer physically overlaps a section of the first repair stringer; and coupling the first repair stringer and the second repair stringer to a stringer of the hat stringer.

[0023] In another aspect, a repair stringer is provided. The repair stringer includes a web section having an internal profile shaped to match the profile of an internal cavity defined by a hat stringer, and at least one of a cap section and a flange section extending from the web section, and wherein the repair stringer has a partial cross-section relative to the overall cross-section of the hat stringer.

[0024] In another aspect, a method is provided. The method includes arranging a first repair stringer such that a section of the first repair stringer is positioned in or adjacent to a plane in which a missing section of a base stringer was previously positioned. The method also includes arranging a second repair stringer and a third repair stringer such that a section of the second repair stringer and a section of the third repair stringer sandwich a section of the first repair stringer positioned in or adjacent to the plane. The method also includes arranging a fourth repair stringer such that a section of the fourth repair stringer and the first repair stringer sandwich the second repair stringer. The method also includes coupling the first repair stringer, the second repair stringer, the third repair stringer, and the fourth repair stringer to the base stringer.

[0025] In yet another aspect, a hat stringer is provided. The hat stringer includes a stringer. The hat stringer also includes at least one repair stringer coupled to the stringer, the repair stringer coupled to the stringer in an installation position that is one of a plurality of possible installation positions along a cross-section of the hat stringer, and in each of the plurality of possible installation positions, the repair stringer is shaped to have an internal profile that matches at least a portion of a profile of an internal cavity defined by the hat stringer. In addition, the cross-sectional area of ​​the repair stringer is less than the total cross-sectional area of ​​the hat stringer. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] For a more detailed understanding of the above-mentioned features, reference may be made to a more detailed description of some exemplary aspects as briefly summarized above, some of which are illustrated in the accompanying drawings.

[0027] Figure 1 is a top plan view of an exemplary aircraft having a wing including at least one hat stringer;

[0028] Figure 2 is a cross-sectional view of a hat-shaped beam;

[0029] Figure 3A and Figure 3B is a cross-sectional view of a hat-type stringer undergoing a full stringer repair using a repair stringer having a "relaxed Z" shape;

[0030] Figure 3C is a cross-sectional view of another hat-type stringer undergoing a full stringer repair using a repair stringer having a "relaxed Z" shape;

[0031] Figure 4A and Figure 4B is a cross-sectional view of a hat-type stringer undergoing a full stringer repair using a repair stringer having a "slow-break L" shape;

[0032] Figure 4C is a cross-sectional view of another hat-type stringer undergoing a full stringer repair using a repair stringer having a "relaxed L" shape and a repair stringer having a "relaxed U" shape;

[0033] Figure 5 is a cross-sectional view of a hat-type stringer undergoing local stringer repair;

[0034] Fig. 6A is a cross-sectional view of a hat-shaped truss that has undergone segment splicing repair;

[0035] Figure 6B is a cross-sectional view of another hat-shaped beam that has undergone segment splicing repair;

[0036] Figure 7is a flow chart of a method of repairing a hat stringer according to one aspect of the present disclosure;

[0037] Figure 8 is a flow chart of a method of repairing a hat stringer according to another aspect of the present disclosure; and

[0038] Fig. 9 is a flow chart of a method of splicing hat stringers according to another aspect of the present disclosure. DETAILED DESCRIPTION

[0039] The present disclosure relates to the repair of hat stringers. In some cases, hat stringers that can support the skin components of an aircraft can become damaged or otherwise require structural reinforcement, for example, due to a collision event during service. Hat stringers can also sometimes be removed to make room for skin repairs. According to the inventive aspects of the present disclosure, hat stringer repair techniques and repair stringers that facilitate the repair or reinforcement of hat stringers are provided herein. Such repair stringers may include an internal geometric profile that matches the inner cavity profile of a stringer (e.g., a Type 1, Type 2, and / or Type 3 stringer). The repair stringers may be arranged so that sections of the repair section, such as a cap section or a web section along the hat stringer, physically overlap each other. The inventive aspects disclosed herein can advantageously minimize the amount of components required and can eliminate or reduce the need for shimming. The reduction in components also reduces the weight of the aircraft, which is also beneficial. Furthermore, the unique geometric profiles of the repair stringers disclosed herein may increase the applicability of repair solutions over larger portions of an aircraft body and, among other advantages, may make inventory repair parts more accessible to airline operators.

[0040] In the present disclosure, reference is made to various aspects. However, it should be understood that the present disclosure is not limited to the specifically described aspects. On the contrary, any combination of the following features and elements (whether or not related to different aspects) is contemplated as implementing and practicing the teachings provided herein. In addition, when the elements of these aspects are described in the form of "at least one of A and B", it will be understood that the aspects exclusively including element A, the aspects exclusively including element B, and the aspects including elements A and B are all considered. In addition, although some aspects can achieve advantages over other possible solutions and / or advantages over the prior art, whether a specific advantage is achieved by a given aspect does not limit the present disclosure. Therefore, the aspects, features, aspects and advantages disclosed herein are merely illustrative and are not considered to be elements or limitations of the appended claims unless explicitly stated in one or more claims. Similarly, reference to "the present invention" should not be interpreted as a summary of any inventive subject matter disclosed herein, and should not be considered to be elements or limitations of the appended claims unless explicitly stated in one or more claims. Furthermore, as used herein, a repair stringer is primarily located on one side of the hat stringer (as defined by the sagittal or median plane) when greater than fifty percent (50%) of its cross-section is located on that side.

[0041] While the foregoing is directed to various aspects of the present disclosure, other and further aspects of the disclosure may be devised without departing from the basic scope thereof, and the scope of the disclosure is determined by the appended claims.

[0042] Now referring to the accompanying drawings, Figure 1 A top plan view of an aircraft 100 is shown according to an exemplary aspect of the present disclosure. As shown, the aircraft 100 includes a fuselage 114 and a pair of wings 110, 112. The wings 110, 112 extend laterally outward from the fuselage 114. The aircraft 100 also includes a tail section 116 having a horizontal tail 118 and a vertical tail 120. The wings 110, 112, the horizontal tail 118, and the vertical tail 120 each include control surfaces 122 (e.g., ailerons, elevators, rudders, etc.) that can be controlled to maneuver the aircraft 100 during flight. The aircraft 100 also includes propulsion units 124, 126 mounted to the respective wings 110, 112. Figure 1 In the exemplary embodiment, the propulsion units 124, 126 are gas turbine engines configured as turbofans. However, in other exemplary aspects, the propulsion units 124, 126 may be other types of propulsion units, such as electrically driven fans.

[0043] Wings 110, 112 each include a skin member 128, which may be formed by various structures such as Figure 1The stringers 130 and ribs 136 (shown in the cross-sectional portion of the wing 112 in FIG. 1 ) are supported internally. The stringers 130 are positioned in spaced relationship to each other and extend generally in the span direction from the inboard portion 132 to the outboard portion 134 of their respective wings 110, 112. One or more stringers 130 may have a hat-shaped cross-section, for example, as viewed in the span direction of their associated wing. In this regard, in some exemplary aspects, the stringers 130 may be "hat-shaped stringers." As shown in FIG. Figure 1 As further depicted in FIG. 1 , the ribs 136 are positioned in spaced relation to one another and extend generally in a chord-wise direction, for example from a forward structure (such as a forward spar 138 ) to a rearward structure (such as a rearward spar 140 ) of their respective wings 110 , 112 .

[0044] Figure 2 is a cross-sectional view of a hat beam 200. For example, a hat beam may be Figure 1 For reference, a first direction D1 (in Figure 2 The first direction D1, the second direction D2 and the third direction D3 are perpendicular to each other and form an orthogonal direction system. Figure 2 In this regard, the first direction D1 is along the span direction of the aircraft wing. Figure 2 A cross section of the hat stringer 200 viewed along the span direction of the wing is depicted. The third direction D3 may be a vertical direction.

[0045] like Figure 2 As depicted, the hat stringer 200 is coupled to a skin member 202 to provide support to the skin member. For example, the skin member 202 may be a lower wing skin of a wing. The hat stringer 130 includes a base stringer 210. The base stringer 210 may be formed of one or more laminated layers (pile), such as one or more carbon fiber reinforced polymer (CFRP) laminated layers. For example, the base stringer 210 may be formed as a one-piece, unitary structure. The base stringer 210 may be formed of one or more laminated layers (pile). Figure 2 2. From left to right in FIG. 2, there are a first flange section 212, a first web section 214, a cover section 216, a second web section 218, and a second flange section 220. The first flange section 212 and the second flange section 220 are coupled to the skin member 202. The first web section 214 and the second web section 218 extend from their respective first flange sections 212 and second flange sections 220 and converge toward each other as they extend away from their respective first flange sections 212 and second flange sections 220. The cover section 216 connects the first web section 214 and the second web section 218 and extends substantially parallel to the first flange section 212 and the second flange section 220 and the skin member 202.

[0046] The base beam 210 and the skin member 202 together define an inner cavity 222. A profile 224 of the inner cavity 222 is defined by the base beam 210. In particular, the profile 224 of the inner cavity 222 viewed along the first direction D1 is defined by an inner surface 226 of the base beam 210 (eg, when in an available state). Figure 2 , a profile 224 of the inner cavity 222 is represented by a dashed line extending along an inner surface 226 of the base beam 210, or more specifically along an inner surface of the first web segment 214 and the second web segment 218 and the cover segment 216. The profile 224 has a first web portion 224A, a cover portion 224B, and a second web portion 224C. The first web portion 224A extends along the inner surface of the first web segment 214, the cover portion 224B extends along the inner surface of the cover segment 216, and the second web portion 224C extends along the inner surface of the second web segment 218. The base beam 210 has an outer surface 228 opposite the inner surface 226. Further, for reference, the hat beam 200 defines a center plane 230 that divides a first side 232 and a second side 234 of the hat beam 200. The center plane 230 is orthogonal to the second direction D2.

[0047] In some cases, hat stringers (such as Figure 2 Hat stringers 200 in an aircraft may become damaged or otherwise require structural reinforcement, for example, due to a collision event during service. For example, sections of the hat stringer 200 may be damaged to the extent that its structural integrity is compromised, or in some extreme cases, completely missing. This may present a safety issue or render the aircraft unsuitable for service. In accordance with inventive aspects of the present disclosure, hat stringer repair techniques and repair stringers are provided herein that facilitate the repair or reinforcement of hat stringers. Exemplary repair techniques and repair stringers are provided below.

[0048] Reference now Figure 3A and Figure 3B , Figure 3A and Figure 3B Depicts a full stringer repair Figure 2 2, the full-stringer repair uses a repair stringer having a "lazy Z" shape. Specifically, the base stringer 210 is subjected to a full-stringer repair by using a first repair stringer 300 and a second repair stringer 310 both having a lazy Z shape. The first repair stringer 300 and the second repair stringer 310 may both be formed of one or more laminate layers, such as one or more carbon fiber laminate layers. The full-stringer repair may be implemented in response to the base stringer 210 being damaged or otherwise structurally unstable.

[0049] like Figure 3A and Figure 3BAs depicted, the first repair stringer 300 has a flange section 302, a web section 304, and a cap section 306. The web section 304 extends between and connects the cap section 306 and the flange section 302. The flange section 302 and the cap section 306 extend generally parallel to each other. The first repair stringer 300 has an interior profile 308 that matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. Figure 3A , the inner profile 308 of the first repair beam 300 is represented by a dashed line extending along the inner surface of the first repair beam 300. In other words, the inner profile 308 of the first repair beam 300 matches or is shaped to complement at least a portion of the outer surface of the beam to which the first repair beam 300 will be disposed adjacent. Figure 3A As depicted, the inner profile 308 of the first repair stringer 300 matches or is shaped to be complementary to at least a portion of the outer surface 228 of the base stringer 210. In addition, the cross-sectional area of ​​the first repair stringer 300 viewed along the first direction D1 (e.g., the span direction of the wing) is less than the total cross-sectional area of ​​the hat stringer 200 viewed along the first direction D1. In this regard, the first repair stringer 300 can be considered to have a partial cross-section relative to the hat stringer 200.

[0050] The second repair stringer 310 has a flange section 312, a web section 314, and a cover section 316. The web section 314 extends between and connects the cover section 316 and the flange section 312. The flange section 312 and the cover section 316 extend generally parallel to each other. Similar to the first repair stringer 300, the second repair stringer 310 has an inner profile 318 that matches at least a portion of the profile 224 of the inner cavity 222 defined by the hat stringer 200. Figure 3A , the inner profile 318 of the second repair beam 310 is represented by a dashed line extending along the inner surface of the second repair beam 310. In other words, the inner profile 318 of the second repair beam 310 matches or is shaped to complement at least a portion of the outer surface of the beam to which the second repair beam 310 will be disposed adjacent. Figure 3A As depicted, the inner profile 318 of the second repair beam 310 matches or is shaped to be complementary to at least a portion of the outer surface 228 of the base beam 210 and at least a portion of the outer surface of the first repair beam 300. In addition, the cross-sectional area of ​​the second repair beam 310 as viewed along the first direction D1 is less than the total cross-sectional area of ​​the hat beam 200 as viewed along the first direction D1. In this regard, the second repair beam 310 can be considered to have a partial cross-section relative to the hat beam 200.

[0051] In addition, Figure 3A and Figure 3BIn the depicted example, the first repair beam 300 and the second repair beam 310 have the same cross-sectional shape viewed along the first direction D1. The second repair beam 310 is oriented to be horizontally flipped relative to the first repair beam 300, or more precisely, the second repair beam 310 is rotated one hundred eighty degrees (180°) relative to the first repair beam 300 about a rotation axis extending along the third direction D3.

[0052] For a full-beam repair using a repair beam having a “slow-fold Z” shape, the full-beam repair may be performed by placing a first repair beam 300 at a first installation position along the cross section of the hat beam 200. For example, Figure 3A As shown, the first repair stringer 300 is shown arranged in a first installation position as indicated by arrow 1. In the first installation position, the first repair stringer 300 is arranged such that the flange section 302, the web section 304, and the cover section 306 respectively face or are respectively positioned adjacent to the first flange section 212, the first web section 214, and the cover section 216 of the base stringer 210. When the first repair stringer 300 is arranged in the first installation position, the flange section 302, the web section 304, and the cover section 306 of the first repair stringer 300 extend parallel to the first flange section 212, the first web section 214, and the cover section 216 of the base stringer 210, respectively.

[0053] A full beam repair using a repair beam having a "slow-bend Z" shape may also be performed by placing a second repair beam 310 at a second installation position along the cross section of the hat beam 200. For example, Figure 3A 2, the second repair beam 310 is shown arranged in the second installation position as indicated by arrow 2. When the second repair beam 310 is arranged in the second installation position, the flange section 312, the web section 314, and the cover section 316 of the second repair beam 310 extend parallel to the second flange section 220, the second web section 218, and the cover section 216 of the base beam 210, respectively. Furthermore, in the second installation position, the second repair beam 310 is arranged such that the web section 314 faces or is positioned adjacent to the second web section 218 of the base beam 210, and such that the cover section 316 faces or is positioned adjacent to the cover section 306 of the first repair beam 300. In this regard, the cover section 316 of the second repair beam 310 physically overlaps the cover section 306 of the first repair beam 300. The cover section 306 of the first repair beam 300 and the cover section 316 of the second repair beam 310 both extend parallel to the cover section 216 of the base beam 210. Furthermore, as depicted, the cover section 306 of the first repair beam 300 is sandwiched between the cover section 316 of the second repair beam 310 and the cover section 216 of the base beam 210, for example, along the third direction D3.

[0054] like Figure 3A and Figure 3B As further shown, the flange section 312 of the second repair beam 310 and the second flange section 220 of the base beam 210 are spaced apart from each other, for example, along the third direction D3. Accordingly, a gap G or vertical offset is defined between the flange section 312 of the second repair beam 310 and the second flange section 220 of the base beam 210. A full beam repair using a repair beam having a "relaxed Z" shape can also be achieved by arranging one or more shims 320 between the second flange section 220 of the base beam 210 and the flange section 312 of the second repair beam 310. That is, one or more shims 320 can be arranged to fill the gap G. For example, as Figure 3A As shown, one or more shims 320 are shown arranged within the gap G as indicated by arrow 3. The added shims 320 can improve the structural integrity of the repaired hat beam 200. In addition, it is worth noting that due to the shape of the first repair beam 300 and the second repair beam 310 and their arrangement in their respective installation positions, the need for shims on both sides of the hat beam 200 can be eliminated or otherwise reduced. For example, in Figure 3A In the example of FIG. 5 , no shim is required between the flange section 302 of the first repair stringer 300 and the first flange section 212 of the base stringer 210 .

[0055] A full beam repair using a repair beam having a "slow-bend Z" shape can also be achieved by coupling the first repair beam 300 and the second repair beam 310 to the base beam 210 at their respective installation locations. Figure 3BAs shown, a plurality of fasteners 330 are used to couple the first repair stringer 300 and the second repair stringer 310 to the base stringer 210. One of the plurality of fasteners 330 may couple the flange section 302 of the first repair stringer 300 to the first flange section 212 of the base stringer 210. One of the plurality of fasteners 330 may couple the web section 304 of the first repair stringer 300 to the first web section 214 of the base stringer 210. One of the plurality of fasteners 330 may couple the cap section 306 of the first repair stringer 300, the cap section 316 of the second repair stringer 310, and the cap section 216 of the base stringer 210 together. One of the plurality of fasteners 330 may couple the web section 314 of the second repair stringer 310 to the second web section 218 of the base stringer 210. Finally, one of the plurality of fasteners 330 may couple the flange section 312 of the second repair beam 310 with the second flange section 220 of the base beam 210. Any suitable type of fastener may be used, including but not limited to rivets, bolts, screws, anchors, etc. In alternative exemplary aspects, the first repair beam 300 and the second repair beam 310 may be coupled to the base beam 210 by other means, such as by a combination of compression and heat treatment.

[0056] In the first repair beam 300 and the second repair beam 310 Figure 3B With the base stringer 210 coupled as depicted in FIG. 2 , the hat stringer 200 may be considered a restored or repaired hat stringer.

[0057] Notably, the first installation position is one of a plurality of possible installation positions along the cross section of the hat stringer 200 in which the first repair stringer 300 may be arranged due at least in part to the geometric arrangement or cross-sectional shape of the first repair stringer 300. In each of the plurality of possible installation positions, the interior profile 308 of the first repair stringer 300 matches the profile 224 of the interior cavity 222 defined by the hat stringer 200.

[0058] As a first exemplary alternative installation position, the first repair stringer 300 may be arranged such that the flange section 302, the web section 304, and the cover section 306 respectively face or are respectively positioned adjacent to the second flange section 220, the second web section 218, and the cover section 216 of the base stringer 210. In this first alternative installation position, the flange section 302, the web section 304, and the cover section 306 of the first repair stringer 300 may respectively extend parallel to the second flange section 220, the second web section 218, and the cover section 216 of the base stringer 210. To arrange the first repair stringer 300 in the first alternative installation position, the first repair stringer 300 may be positioned relative to the flange section 302, the web section 304, and the cover section 306 of the base stringer 210. Figure 3A and Figure 3B , its orientation as shown in FIG. 3 may be flipped horizontally (or more precisely, the first repair beam 300 may be rotated from its orientation in FIG. 3 to its orientation in FIG. 4 ). Figure 3A and Figure 3B The first repair stringer 300 is oriented one hundred eighty degrees (180°) in the orientation of the first repair stringer 300. In the first alternative installation position, the interior profile 308 of the first repair stringer 300 will still match the profile 224 of the interior cavity 222 defined by the hat stringer 200. Accordingly, the first repair stringer 300 is geometrically shaped to be mountable to the hat stringer 200 in at least a first possible installation position in which the first repair stringer 300 is primarily positioned on the first side 232 of the hat stringer 200 (i.e., more than fifty percent (50%) of the cross-section of the first repair stringer 300 is positioned on the first side 232), and a second possible installation position in which the first repair stringer 300 is primarily positioned on the second side 234 of the hat stringer 200 (i.e., more than fifty percent (50%) of the cross-section of the first repair stringer 300 is positioned on the second side 234).

[0059] As a second exemplary alternative mounting location, Figure 3C As shown, the first repair stringer 300 may be arranged such that when the first repair stringer 300 is arranged in the second alternative installation position, the flange section 302, the web section 304, and the cover section 306 of the first repair stringer 300 extend parallel to but not in contact with the first flange section 212, the first web section 214, and the cover section 216 of the base stringer 210, respectively. Further, in the second alternative installation position, the first repair stringer 300 is arranged such that the web section 304 faces or is positioned adjacent to the first web section of another repair stringer 340 (e.g., the first existing repair stringer), and such that the cover section 306 faces or is positioned adjacent to the cover section of yet another repair stringer 350 (e.g., the second existing repair stringer). In this regard, the cover section 306 of the first repair stringer 300 physically overlaps with, for example, the cover section of the second existing repair stringer 350. In the second alternative installation position, the interior profile 308 of the first repair stringer 300 will still match the profile 224 of the interior cavity 222 defined by the hat stringer 200. Accordingly, the first repair stringer 300 is geometrically shaped to be mountable to the hat stringer 200 in an installation position in which the first repair stringer 300 is stacked on other stringers (e.g., existing repair stringers) that are not the base stringer 210.

[0060] As a third exemplary alternative installation position, the first repair beam 300 may be arranged at the second installation position, or more specifically, may be arranged at Figure 3A and Figure 3BThe second repair beam 310 is located at the installation position of the second repair beam 310, and the second repair beam 310 can be installed in another possible installation position of multiple possible installation positions. Accordingly, like the first repair beam 300, the second repair beam 310 can also be installed in multiple possible positions, as understood by the above teachings.

[0061] In some exemplary aspects, at each of the plurality of possible installation positions in which the first repair stringer 300 may be installed, the web section 304 of the first repair stringer 300 extends parallel to the web section of the base stringer 210. In other words, in some exemplary aspects, at each of the plurality of possible installation positions in which the first repair stringer 300 may be installed, the inner surface of the web section 304 of the first repair stringer 300 extends parallel to the web portion of the profile 224. The same is true for the second repair stringer 310. That is, at each of the plurality of possible installation positions in which the second repair stringer 310 may be installed, the web section 314 of the second repair stringer 310 extends parallel to the web section of the base stringer 210. In other words, in some exemplary aspects, at each of the plurality of possible installation positions in which the second repair stringer 310 may be installed, the inner surface of the web section 314 of the second repair stringer 310 extends parallel to the web portion of the profile 224.

[0062] In still other exemplary aspects, at each of the plurality of possible installation positions at which the first repair beam 300 may be installed, the cover section 306 of the first repair beam 300 extends parallel to the cover section 216 of the base beam 210, and the flange section 302 of the first repair beam 300 extends parallel to the flange section of the base beam 210. The same is true for the second repair beam 310. Specifically, at each of the plurality of possible installation positions at which the second repair beam 310 may be installed, the cover section 316 of the second repair beam 310 extends parallel to the cover section 216 of the base beam 210, and the flange section 312 of the second repair beam 310 extends parallel to the flange section of the base beam 210.

[0063] Repairing a hat stringer using one or more repair stringers each having a slow-break Z cross-sectional shape may present certain advantages. For example, the slow-break Z-shaped partial cross-section allows the repair stringer to be installed at multiple installation locations along the cross-section of the hat stringer, which provides flexibility in the repair process. In addition, the gap filling required for the repair may be reduced compared to conventional techniques. For example, in Figure 3BIn the embodiment of the present invention, the shim 320 is required on only one side of the hat beam because the flange section 302 of the first repair beam 300 can be directly arranged on or adjacent to the first flange section 212 of the base beam 210. Moreover, the repair beam having a slow-break Z cross-sectional shape includes three sections that can contact three corresponding sections of one or more other beams. The three contact points can provide structural stability for the repaired hat beam. In addition, it is advantageous to repair the hat beam using multiple slow-break Z-shaped repair beams because such hat beams can be stacked (e.g., as shown in FIG. 1 ). Figure 3C The invention can significantly reduce or eliminate the need for custom repair stringers for stacking arrangements by providing a plurality of Z-repair stringers of the same shape without changing the shape or angle of the repair stringer. In other words, multiple Z-repair stringers of the same shape can be used for stacking repairs. Among other advantages, such advantages can also improve the convenience of inventorying and storing repair parts and operators performing repair processes.

[0064] Reference now Figure 4A and Figure 4B , Figure 4A and Figure 4B Depicts a full stringer repair Figure 2 2, the full-stringer repair uses a repair stringer having a "lazy L" shape. Specifically, the base stringer 210 is subjected to a full-stringer repair by using a first repair stringer 400, a second repair stringer 410, a third repair stringer 420, and a fourth repair stringer 430, wherein the first repair stringer 400, the second repair stringer 410, the third repair stringer 420, and the fourth repair stringer 430 all have a lazy L shape, or more precisely, have a lazy L cross-section viewed along the first direction D1. The first repair stringer 400, the second repair stringer 410, the third repair stringer 420, and the fourth repair stringer 430 may each be formed of one or more laminate layers, such as one or more carbon fiber laminate layers. The full-stringer repair may be implemented in response to the base stringer 210 becoming damaged or otherwise structurally unstable.

[0065] like Figure 4A and Figure 4BAs depicted, in general, first repair stringer 400, second repair stringer 410, third repair stringer 420, and fourth repair stringer 430 each include a web section and a second section, which second section may be a flange section or a cap section depending on the orientation of the repair stringer. The second section of a given repair stringer is not parallel to its web section. An obtuse angle is defined between the web section and the second section of the respective repair stringers of first repair stringer 400, second repair stringer 410, third repair stringer 420, and fourth repair stringer 430. In particular, as shown, first repair stringer 400 has web section 404 and a second section, which in this example is flange section 402. Second repair stringer 410 has web section 414 and a second section, which in this example is cap section 416. The third repair stringer 420 has a web section 424 and a second section, which in this example is the flange section 422. The fourth repair stringer 430 has a web section 434 and a second section, which in this example is the cap section 436.

[0066] The first repair stringer 400 has an interior profile 408 that matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. Figure 4A , the interior profile 408 of the first repair stringer 400 is represented by a dashed line extending along the interior surface of the first repair stringer 400. As depicted, the interior profile 408 of the first repair stringer 400 matches or is shaped to be complementary to at least the first web portion 224A of the profile 224. In other words, the interior profile 408 of the first repair stringer 400 matches or is shaped to be complementary to at least a portion of the exterior surface of the stringer (or stringers) to which the first repair stringer 400 will be disposed adjacent. For example, Figure 4A As depicted, the interior profile 408 of the first repair stringer 400 matches or is shaped complementary to at least a portion of the exterior surface 228 of the base stringer 210 .

[0067] The second repair stringer 410 has an interior profile 418 that matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. Figure 4A , the inner profile 418 of the second repair stringer 410 is represented by a dashed line extending along the inner surface of the second repair stringer 410. As shown, the inner profile 418 of the second repair stringer 410 matches or is shaped to be complementary to at least the first web portion 224A and the cap portion 224B of the profile 224. In other words, the inner profile 418 of the second repair stringer 410 matches or is shaped to be complementary to at least a portion of the outer surface of the stringer (or multiple stringers) to which the second repair stringer 410 will be disposed adjacent. For example, as shown in FIG. Figure 4AAs depicted, the interior profile 418 of the second repair beam 410 matches or is shaped complementary to at least a portion of the exterior surface 228 of the base beam 210 along the cover segment 216 and at least a portion of the exterior surface of the first repair beam 400 .

[0068] The third repair stringer 420 has an interior profile 428 that matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. Figure 4A , the inner profile 428 of the third repair stringer 420 is represented by a dashed line extending along the inner surface of the third repair stringer 420. As depicted, the inner profile 428 of the third repair stringer 420 matches or is shaped to be complementary to at least the second web portion 224C of the profile 224. In other words, the inner profile 428 of the third repair stringer 420 matches or is shaped to be complementary to at least a portion of the outer surface of the stringer (or multiple stringers) to which the third repair stringer 420 will be disposed adjacent. For example, as Figure 4A As depicted, the inner profile 428 of the third repair stringer 420 matches or is shaped complementary to at least a portion of the outer surface 228 of the base stringer 210 .

[0069] The fourth repair stringer 430 has an interior profile 438 that matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. Figure 4A , the inner profile 438 of the fourth repair stringer 430 is represented by a dashed line extending along the inner surface of the fourth repair stringer 430. As shown, the inner profile 438 of the fourth repair stringer 430 matches or is shaped to be complementary to at least the second web portion 224C and the cap portion 224B of the profile 224. In other words, the inner profile 438 of the fourth repair stringer 430 matches or is shaped to be complementary to at least a portion of the outer surface of the stringer (or multiple stringers) to which the fourth repair stringer 430 will be disposed adjacent. For example, as shown in FIG. Figure 4A As depicted, the inner profile 438 of the fourth repair beam 430 matches or is shaped complementary to at least a portion of the outer surface of the third repair beam 420 and at least a portion of the outer surface of the second repair beam 410 .

[0070] In addition, Figure 4A and Figure 4B In the example depicted in FIG. 1 , the cross-sectional area of ​​the first repair stringer 400 observed along the first direction D1 (e.g., the span direction of the wing) is smaller than the total cross-sectional area of ​​the hat stringer 200 observed along the first direction D1. The same is true for the second repair stringer 410, the third repair stringer 420, and the fourth repair stringer 430. Therefore, the first repair stringer 400, the second repair stringer 410, the third repair stringer 420, and the fourth repair stringer 430 can all be regarded as having a partial cross-section relative to the hat stringer 200.

[0071] Furthermore, in some exemplary aspects, such as in Figure 4A and Figure 4B In the example of , the first repair beam 400 , the second repair beam 410 , the third repair beam 420 , and the fourth repair beam 430 may all have the same cross-sectional shape as viewed along the first direction D1 . Figure 4A and Figure 4B , the second repair beam 410 is oriented to be flipped vertically relative to the first repair beam 400, or more precisely, the second repair beam 410 is rotated one hundred eighty degrees (180°) relative to the first repair beam 400 about the rotation axis extending along the second direction D2. The third repair beam 420 is oriented to be flipped horizontally relative to the first repair beam 400, or more precisely, the third repair beam 420 is rotated one hundred eighty degrees (180°) relative to the first repair beam 400 about the rotation axis extending along the third direction D3. The fourth repair beam 430 is oriented to be flipped vertically and horizontally relative to the first repair beam 400, or more precisely, the fourth repair beam 430 is rotated 180 degrees (180°) relative to the first repair beam 400 about the rotation axis extending along the third direction D3 for horizontal flipping, and the fourth repair beam 430 is rotated 180 degrees (180°) relative to the first repair beam 400 about the rotation axis extending along the second direction D2 for vertical flipping.

[0072] For a full-beam repair using a repair beam having a "slow-bend L" shape, the full-beam repair may be performed by placing a first repair beam 400 at a first installation position along the cross section of the hat beam 200. For example, Figure 4A As shown, the first repair stringer 400 is shown arranged in a first installation position as indicated by arrow 1. In the first installation position, the first repair stringer 400 is arranged such that the flange section 402 and the web section 404 respectively face or are respectively positioned adjacent to the first flange section 212 and the first web section 214 of the base stringer 210. When the first repair stringer 400 is arranged in the first installation position, the flange section 402 and the web section 404 of the first repair stringer 400 extend parallel to the first flange section 212 and the first web section 214 of the base stringer 210, respectively.

[0073] A full beam repair using a repair beam having a "slow-bend L" shape may also be performed by placing a second repair beam 410 at a second installation position along the cross section of the hat beam 200. For example, Figure 4A2, the second repair stringer 410 is shown arranged in the second installation position as indicated by arrow 2. In the second installation position, the second repair stringer 410 is arranged such that the web section 414 and the cover section 416 of the second repair stringer 410 extend parallel to the first web section 214 and the cover section 216 of the base stringer 210, respectively. Furthermore, in the second installation position, the second repair stringer 410 is arranged such that the web section 414 faces or is positioned adjacent to the web section 404 of the first repair stringer 400. In this regard, the web section 414 of the second repair stringer 410 physically overlaps the web section 404 of the first repair stringer 400, wherein the web section 404 is sandwiched or positioned between the web section 414 and the first web section 214 of the base stringer 210. Furthermore, in the second installed position, the second repair beam 410 is arranged such that the cover section 416 faces or is positioned adjacent to the cover section 216 of the base beam 210 .

[0074] A full beam repair using a repair beam having a "slow-bend L" shape can also be implemented by placing a third repair beam 420 at a third installation position along the cross section of the hat beam 200. For example, Figure 4A As shown, the third repair stringer 420 is shown arranged in the third installation position as indicated by arrow 3. In the third installation position, the third repair stringer 420 is arranged so that the flange section 422 and the web section 424 respectively face or are respectively positioned adjacent to the second flange section 220 and the second web section 218 of the base stringer 210. When the third repair stringer 420 is arranged in the third installation position, the flange section 422 and the web section 424 of the third repair stringer 420 extend parallel to the second flange section 220 and the second web section 218 of the base stringer 210, respectively.

[0075] A full beam repair using a repair beam having a "slow-bend L" shape can also be implemented by placing a fourth repair beam 430 at a fourth installation position along the cross section of the hat beam 200. For example, Figure 4A2, the fourth repair stringer 430 is shown arranged in a fourth installation position as indicated by arrow 4. In the fourth installation position, the fourth repair stringer 430 is arranged such that the web section 434 and the cover section 436 of the fourth repair stringer 430 extend parallel to the second web section 218 and the cover section 216 of the base stringer 210, respectively. Furthermore, in the fourth installation position, the fourth repair stringer 430 is arranged such that the web section 434 faces or is positioned adjacent to the web section 424 of the third repair stringer 420. In this regard, the web section 434 of the fourth repair stringer 430 physically overlaps the web section 424 of the third repair stringer 420, wherein the web section 424 is sandwiched or positioned between the web section 434 and the second web section 218 of the base stringer 210. Furthermore, in the fourth installed position, the fourth repair beam 430 is arranged such that the cover section 436 faces or is positioned adjacent to the cover section 416 of the second repair beam 410. The cover section 436 of the fourth repair beam 430 is spaced apart from the cover section 216 of the base beam 210, for example, along the third direction D3.

[0076] A full-beam repair using a repair beam having a "slow-bend L" shape may also be performed by coupling the first repair beam 400, the second repair beam 410, the third repair beam 420, and the fourth repair beam 430 to the base beam 210 at their respective installation locations. Figure 4BAs shown, a plurality of fasteners 440 are used to couple the first repair stringer 400, the second repair stringer 410, the third repair stringer 420, and the fourth repair stringer 430 to the base stringer 210. One of the plurality of fasteners 440 may couple the flange section 402 of the first repair stringer 400 to the first flange section 212 of the base stringer 210. One of the plurality of fasteners 440 may couple the web section 404 of the first repair stringer 400, the web section 414 of the second repair stringer 410, and the first web section 214 of the base stringer 210. One of the plurality of fasteners 440 may couple the cap section 416 of the second repair stringer 410, the cap section 436 of the third repair stringer 430, and the cap section 216 of the base stringer 210. One of the plurality of fasteners 440 may couple the web section 424 of the third repair stringer 420, the web section 434 of the fourth repair stringer 430, and the second web section 218 of the base stringer 210. Finally, one of the plurality of fasteners 440 may couple the flange section 422 of the third repair stringer 420 with the second flange section 220 of the base stringer 210. Any suitable type of fastener may be used, including but not limited to rivets, bolts, screws, anchors, etc. In alternative exemplary aspects, the first repair stringer 400, the second repair stringer 410, the third repair stringer 420, and / or the fourth repair stringer 430 may be coupled to the base stringer 210 in other ways, such as by a combination of compression processing and heat treatment.

[0077] When the first repair beam 400, the second repair beam 410, the third repair beam 420 and the fourth repair beam 430 are connected as shown in FIG. Figure 4B With the base stringer 210 coupled as depicted in FIG. 2 , the hat stringer 200 may be considered a restored or repaired hat stringer.

[0078] Notably, due at least in part to the geometric arrangement or cross-sectional shape of the first repair stringer 400, the first installation position is one of a plurality of possible installation positions along the cross-section of the hat stringer 200 in which the first repair stringer 400 may be arranged. In each of the plurality of possible installation positions, the interior profile 408 of the first repair stringer 400 matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. For example, the first repair stringer 400 may be flipped vertically and / or horizontally to be installed in the Figure 4A and Figure 4B22, and in any of these other possible installation positions, the interior profile of the first repair beam 400 matches or is shaped to be complementary to at least a portion of the profile 224 of the inner cavity 222. The same is true for the second repair beam 410, the third repair beam 420, and the fourth repair beam 430. In this way, each of the first repair beam 400, the second repair beam 410, the third repair beam 420, and the fourth repair beam 430 can be installed in multiple installation positions along the cross-section of the hat beam 200.

[0079] Repairing a hat beam using one or more repair beams each having a slow-break L-shaped cross-sectional shape can present certain advantages. For example, the slow-break L-shaped partial cross-section allows the repair beam to be installed in multiple installation positions along the cross-section of the hat beam, which provides flexibility in the repair process. In addition, the gap filling required for the repair can be eliminated or otherwise significantly reduced. For example, in Figure 4B In the embodiment of the present invention, no caulking is required to repair the hat-type stringer. In addition, the repair stringer having a slow-break L-shaped cross-sectional shape includes two sections that can contact two corresponding sections of one or more other stringers. The two contact points can provide structural stability for the repaired hat-type stringer. In addition, the repair of the hat-type stringer having multiple slow-break L-shaped repair stringers is advantageous because such hat-type stringers can be stacked without changing the shape or angle of the repair stringer, which can significantly reduce or eliminate the need for customized repair stringers for stacking arrangements. Among other advantages, such advantages can improve the convenience of inventorying and storing repair parts and operators performing repair processes.

[0080] Figure 4C is a cross-sectional view of another hat beam undergoing a full beam repair using a repair beam having a "lazy L" shape and a repair beam having a "lazy U" shape. Figure 4A and Figure 4B The base beam 210 is in the process of undergoing full beam repair by first repair beam 400 and second repair beam 420. The first repair beam 400 and second repair beam 420 both have a slow-bend L shape, or more precisely, a slow-bend L cross section viewed along the first direction D1. The third repair beam 450 has a slow-bend U shape, or more precisely, a slow-bend U cross section viewed along the first direction D1. For example, Figure 4CAs shown, the third repair stringer 450 may be arranged in an inverted orientation or in an inverted relief U. The first repair stringer 400, the second repair stringer 420, and the third repair stringer 450 may each be formed of one or more laminate layers, such as one or more carbon fiber laminate layers. A full stringer repair may be performed in response to the base stringer 210 becoming damaged or otherwise structurally unstable.

[0081] The first repair beam 400 and the second repair beam 420 may refer to Figure 4A and Figure 4B Arranged as described above. The third repair stringer 450 includes a first web section 454, a cap section 456, and a second web section 458. The cap section 456 extends between and connects the first web section 454 and the second web section 458. A first obtuse angle is defined between the first web section 454 and the cap section 456. A second obtuse angle is defined between the second web section 458 and the cap section 456. Figure 4C , the third repair stringer 450 does not include a flange section.

[0082] The third repair stringer 450 has an interior profile 460 that matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. Figure 4C , the inner profile 460 of the third repair stringer 450 is represented by a dashed line extending along the inner surface of the third repair stringer 450. As depicted, the inner profile 460 of the third repair stringer 450 matches or is shaped to be complementary to the first web portion 224A, the cap portion 224B, and the second web portion 224C of the profile 224. In other words, the inner profile 460 of the third repair stringer 450 matches or is shaped to be complementary to the outer surface of the stringer (or multiple stringers) to which the third repair stringer 450 will be disposed adjacent. For example, as Figure 4C As depicted, the inner profile 460 of the third repair beam 450 matches or is shaped complementary to at least a portion of the outer surface of the first repair beam 400 , at least a portion of the outer surface of the base beam 210 , and at least a portion of the outer surface of the second repair beam 420 .

[0083] Accordingly, a repair stringer having a relieved U-shape may be arranged such that its first web section is coupled to the web section of one repair stringer, its cap section is coupled to and spans the full length of the cap section of the base stringer, and its second web section is coupled to the web section of another repair stringer. Among other benefits, such an arrangement may provide favorable structural integrity at the cap section and web section of the repaired hat stringer.

[0084] Reference now Figure 5 , Figure 5 Depicts a partial stringer repair Figure 2 In the embodiment of the present invention, the base beam 210 is subjected to a partial beam repair using at least one repair beam having a "relaxed L" shape. Specifically, the base beam 210 is subjected to a partial beam repair using a single repair beam (in this example, a first repair beam 500) having a "relaxed L" shape, or more specifically, a "relaxed L" cross-section, as viewed along the first direction D1. The first repair beam 500 may be formed of one or more laminate layers, such as one or more carbon fiber laminate layers. The partial beam repair may be performed in response to the base beam 210 becoming damaged or otherwise structurally unstable (e.g., due to a Figure 5 In this example, the damaged portion 204 is located at the transition between the first flange section 212 and the first web section 214, but in other examples may be located in other areas along the cross section of the hat stringer 200. In addition, in some alternative exemplary aspects, a repair stringer having a "relaxed Z" shape may be used for local stringer repair.

[0085] like Figure 5 As depicted Figure 4A and Figure 4B In the repair stringers 400, 410, 420, 430, the first repair stringer 500 includes a first section (e.g., a web section) and a second section, which may be a flange section or a cap section depending on the orientation of the first repair stringer 500. The second section of the first repair stringer 500 is not parallel to the first section thereof. An obtuse angle is defined between the first section and the second section of the first repair stringer 500. Figure 5 In the example of FIG. 5 , the first section of the first repair stringer 500 is the web section 504 and the second section is the flange section 502 .

[0086] The first repair stringer 500 has an interior profile 508 that matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. Figure 5 , the interior profile 508 of the first repair stringer 500 is represented by a dashed line extending along the interior surface of the first repair stringer 500. As depicted, the interior profile 508 of the first repair stringer 500 matches or is shaped to be complementary to at least the first web portion 224A of the profile 224. In other words, the interior profile 508 of the first repair stringer 500 matches or is shaped to be complementary to at least a portion of the exterior surface of the stringer (or multiple stringers) to which the first repair stringer 500 will be disposed adjacent. For example, Figure 5 As depicted, the interior profile 508 of the first repair stringer 500 matches or is shaped to complement at least a portion of the exterior surface 228 of the base stringer 210. Figure 5In the depicted example, the cross-sectional area of ​​the first repair stringer 500 viewed along the first direction D1 (eg, the span direction of the wing) is smaller than the total cross-sectional area of ​​the hat stringer 200 viewed along the first direction D1.

[0087] For a local stringer repair using a repair stringer having a "slow-fold L" shape, the local stringer repair may be implemented by placing a first repair stringer 500 at a first installation position along the cross section of the hat stringer 200. For example, Figure 5 As shown, the first repair stringer 500 is shown arranged in a first installation position as indicated by arrow 1. In the first installation position, the first repair stringer 500 is arranged so that the flange section 502 and the web section 504 respectively face or are respectively positioned adjacent to the first flange section 212 and the first web section 214 of the base stringer 210. When the first repair stringer 500 is arranged in the first installation position, the flange section 502 and the web section 504 of the first repair stringer 500 extend parallel to the first flange section 212 and the first web section 214 of the base stringer 210, respectively.

[0088] A localized beam repair using a repair beam having a "slow-bend L" shape may also be performed by coupling a first repair beam 500 to a base beam 210 at a first installation position. Figure 5 As shown, a plurality of fasteners 520 are used to couple the first repair stringer 500 to the base stringer 210. One of the plurality of fasteners 520 may couple the flange section 502 of the first repair stringer 500 to the first flange section 212 of the base stringer 210. One of the plurality of fasteners 520 may couple the web section 504 of the first repair stringer 500 to the first web section 214 of the base stringer 210. Any suitable type of fastener may be used, including but not limited to rivets, bolts, screws, anchors, etc. In alternative exemplary aspects, the first repair stringer 500 may be coupled to the base stringer 210 in other ways, such as by a combination of a compression process and a heat treatment. In the case where the first repair stringer 500 is coupled to the base stringer 210 as shown in FIG. Figure 5 With the depicted coupling, the hat stringer 200 may be considered a restored or repaired hat stringer.

[0089] Notably, the first installation position is one of a plurality of possible installation positions along the cross-section of the hat stringer 200 in which the first repair stringer 500 may be arranged, due at least in part to the geometric arrangement or cross-sectional shape of the first repair stringer 500. In each of the plurality of possible installation positions, the interior profile 508 of the first repair stringer 500 matches at least a portion of the profile 224 of the interior cavity 222 defined by the hat stringer 200. The first repair stringer 500 may be flipped vertically and / or horizontally for installation in another possible installation position.

[0090] As an example, the first repair stringer 500 may be flipped horizontally and arranged so that the web section 504 and the flange section 502 are aligned parallel to the second web section 218 and the second flange section 220 of the base stringer 210, for example, to repair damage to the transition between the second web section 218 and the second flange section 220 of the base stringer 210. As another example, the first repair stringer 500 may be flipped vertically and arranged so that the web section 504 and the second section thereof are aligned parallel to the first web section 214 and the cap section 216 of the base stringer 210, for example, to repair damage to the transition between the first web section 214 and the cap section 216 of the base stringer 210. As yet another example, the first repair stringer 500 may be flipped vertically and horizontally and arranged so that the web section 504 and its second section are aligned parallel to the second web section 218 and the cap section 216 of the base stringer 210, respectively, for example to repair damage to the transition between the second web section 218 and the cap section 216 of the base stringer 210. In any possible installation position, the interior profile of the first repair stringer 500 matches or is shaped to complement at least a portion of the profile 224 of the inner cavity 222.

[0091] Using the repair stringer disclosed herein (such repair stringer having a relieved L-section shape or a relieved Z-section shape) to partially repair a hat stringer may present certain advantages. For example, the repair stringer disclosed herein has a partial cross-section relative to the overall cross-section of the hat stringer, which allows the repair stringer to be strategically arranged or positioned to a damaged section of the hat stringer. This enables a reduction in the material used for the repair, which may advantageously reduce the weight of the aircraft.

[0092] Reference now Fig. 6A , Fig. 6A Depicts a repaired Figure 2The hat beam 200 in the present invention uses a repair beam having a "relaxed L" shape. Specifically, the base beam 210 is subjected to a splicing repair process by a plurality of strategically arranged and oriented repair beams, the repair beams including a first group of repair beams 600 mainly arranged at the first side 232 of the hat beam 200 that needs splicing repair and a second group of repair beams 602 mainly arranged at the second side 234 of the hat beam. The first group 600 includes a first repair beam 610, a second repair beam 620, a third repair beam 630, and a fourth repair beam 640. The first repair beam 610, the second repair beam 620, the third repair beam 630, and the fourth repair beam 640 are all shaped to have an internal profile that matches at least a portion of the profile 224 of the inner cavity 222 defined by the hat beam 200, regardless of their respective installation positions or orientations. In some aspects, the first repair stringer 610, the second repair stringer 620, the third repair stringer 630, and the fourth repair stringer 640 all have the same cross-sectional shape as each other, for example, the cross-sectional shape viewed along a first direction D1, which may be along the span direction of an aircraft wing.

[0093] The second group 602 includes a first repair stringer 650, a second repair stringer 660, a third repair stringer 670, and a fourth repair stringer 680. The repair stringers 610, 620, 630, 640, 650, 660, 670, 680 (or 610-680) can each be formed of one or more laminate layers (such as one or more carbon fiber laminate layers). The first repair stringer 650, the second repair stringer 660, the third repair stringer 670, and the fourth repair stringer 680 are each shaped to have an internal profile that matches at least a portion of the profile 224 of the inner cavity 222 defined by the hat stringer 200, regardless of their respective installation positions or orientations. In some aspects, the first repair stringer 650, the second repair stringer 660, the third repair stringer 670, and the fourth repair stringer 680 all have the same cross-sectional shape as each other, for example, a cross-sectional shape viewed along a first direction D1, which can be a spanwise direction along a wing of an aircraft.

[0094] The splice repair may be in response to a base stringer 210 being damaged due to a missing section such as Fig. 6A The missing section 206 shown becomes damaged. Fig. 6A In the example of , the first web section, the cap section, and the second web section of the base stringer 210 are missing and thus collectively form a missing section 206 or void in the base stringer 210. The plane 208 may define where the missing section 206 of the base stringer 210 was previously located. The plane 208 is defined by Fig. 6A The dashed line in .

[0095] For a splice repair using a repair stringer having a "relaxed L" shape, the splice repair may be implemented by constructing a first set 600 of repair stringers. Specifically, constructing the first set 600 may include arranging the first repair stringers 610 so that a section (e.g., a web section 614) of the first repair stringer 610 is positioned in or adjacent to the plane 208 in which the missing section 206 of the base stringer 210 was previously positioned. Fig. 6A , the web section 614 of the first repair stringer 610 is at least partially positioned in the plane 208 in which the first web section of the base stringer 210 was previously positioned.

[0096] Constructing first group 600 may also include arranging second repair stringer 620 and third repair stringer 630 such that a section of second repair stringer 620 and a section of third repair stringer 630 (e.g., web section 624 of second repair stringer 620 and web section 634 of third repair stringer 630) sandwich a section of first repair stringer 610 (e.g., web section 614) positioned within plane 208. Fig. 6A As depicted, the third repair section 630 has a flange section 632 that faces or is positioned adjacent to the first flange section 212 of the base stringer 210. The second repair section 620 has a flange section 622 that faces or is positioned adjacent to the flange section 632 of the third repair section 630. The flange sections 622, 632 are arranged relative to the first flange section 212 such that a space or gap is defined between the web sections 624, 634. The gap between the web sections 624, 634 is sized such that the web section 614 of the first repair section 610 can be received in the gap, or more specifically, such that the web section 614 can be sandwiched therebetween. Positioning the web section 614 between the web sections 624, 634 can advantageously enhance the structural integrity of the hat stringer 200.

[0097] Constructing the first set 600 of repair stringers along the first side 232 may also include arranging the fourth repair stringer 640 such that a section of the fourth repair stringer 640 (e.g., web section 644) and a section of the first repair stringer 610 (e.g., web section 614) sandwich the second repair stringer 620 (e.g., web section 624). Fig. 6AAs shown, the first repair stringer 610 and the fourth repair stringer 640 are arranged to define a space or gap between their respective web sections 614, 644. The size of the gap between the web sections 614, 644 is designed so that the web section 624 of the second repair section 620 can be received in the gap, or more precisely, so that the web section 624 can be sandwiched therebetween. Positioning the web section 624 between the web sections 614, 644 can advantageously enhance the structural integrity of the hat stringer 200.

[0098] like Fig. 6A As shown, in the case where the first repair beam 610, the second repair beam 620, the third repair beam 630 and the fourth repair beam 640 are arranged as mentioned above, the second repair beam 620 and the third repair beam 630 have the same installation orientation, and the first repair beam 610 and the fourth repair beam 640 have the same installation orientation. As shown in the figure, the second repair beam 620 and the third repair beam 630 are oriented to be vertically and horizontally flipped relative to the first repair beam 610 and the fourth repair beam 640.

[0099] Constructing the first set 600 of repair beams along the first side 232 may also include coupling a first repair beam 610, a second repair beam 620, a third repair beam 630, and a fourth repair beam 640 to the base beam 210. For example, Fig. 6A As shown, a plurality of fasteners 690 are used to couple the first group 600 of first repair stringers 610, second repair stringers 620, third repair stringers 630, and fourth repair stringers 640 to the base stringer 210. One fastener in the plurality of fasteners 690 may couple the flange section 622 of the second repair stringer 620 and the flange section 632 of the third repair stringer 630 to the first flange section 212 of the base stringer 210. One fastener in the plurality of fasteners 690 may couple the web sections 614, 624, 634, 644 of the first repair stringer 610, the second repair stringer 620, the third repair stringer 630, and the fourth repair stringer 640. Since the first repair beam 610 and the fourth repair beam 640 are coupled to the second repair beam 620 and the third repair beam 630 coupled to the base beam 210, the first repair beam 610 and the fourth repair beam 640 are also coupled to the base beam 210. Any suitable type of fastener may be used, including but not limited to rivets, bolts, screws, anchors, etc. In alternative exemplary aspects, the first repair beam 610, the second repair beam 620, the third repair beam 630, and / or the fourth repair beam 640 of the first group 600 may be coupled to the base beam 210 in other ways, such as by a combination of compression treatment and heat treatment.

[0100] With the first group 600 of first, second, third, 630 and / or fourth repair stringers 610 , 620 , 630 , and / or 640 repair stringers in place and coupled to the base stringer 210 , the first group 600 may be viewed as repairing a first portion of the cap section and the first web section of the base stringer 210 .

[0101] The splice repair may also be performed by constructing a second set 602 of repair stringers. Specifically, constructing the second set 602 may include arranging the first repair stringer 650, the second repair stringer 660, the third repair stringer 670, and the fourth repair stringer 680 as described above with respect to the first set 600, and further coupling them to the base stringer 210, for example, to the second flange section 220 thereof.

[0102] With the first repair beam 610 and the fourth repair beam 640 of the first set 600 arranged as mentioned above, a gap is defined between their respective cover sections 616, 646. Fig. 6A In the example of FIG. 6 , the gap defined between the cover segments 616, 646 is arranged along the plane 208 in which the missing section 206 of the base beam 210 was previously positioned. The size of the gap (e.g., along the third direction D3) is designed to be able to receive a portion of another repair beam, such as the cover segment 656 of the first repair beam 650 from the second set 602, as shown in FIG. Fig. 6A In addition, when the first repair beam 650 and the fourth repair beam 680 of the second group 602 are arranged as mentioned above, a gap is defined between their respective cover sections 656, 686. Fig. 6A In the example of FIG. 6 , the gap defined between the cover segments 616, 646 is arranged along the plane 208 in which the missing section 206 of the base beam 210 was previously positioned. The gap is sized (e.g., along the third direction D3) to receive a portion of another repair beam, such as the cover segment 646 of the fourth repair beam 640 from the first set 600, as shown in FIG. Fig. 6A shown.

[0103] like Fig. 6A Additionally depicted, the inner surface of the cap segment 686 of the fourth repair beam 680 of the second group 602 faces or is positioned adjacent to the outer surface of the cap segment 646 of the fourth repair beam 640 of the first group 600. In this regard, the cap segment 686 of the fourth repair beam 680 of the second group 602 physically overlaps the cap segment 646 of the fourth repair beam 640 of the first group 600. The cap segment 646 of the fourth repair beam 640 of the first group 600 physically overlaps the cap segment 656 of the first repair beam 650 of the second group 602. The cap segment 656 of the first repair beam 650 of the second group 602 physically overlaps the cap segment 616 of the first repair beam 610 of the first group 600.

[0104] In addition, if Fig. 6A As shown, the cap segments 616, 656, 646, 686 of each of the repair stringers 610, 650, 640, 680 extend from their primary sides across the center plane 230. For example, the first repair segment 610 is primarily positioned on the first side 232 of the hat stringer 200, but the end of the cap segment 616 extends across the center plane 230 to the second side 234. The first repair segment 650 is primarily positioned on the second side 234 of the hat stringer 200, but the end of the cap segment 656 extends across the center plane 230 to the first side 232. Similarly, the fourth repair segment 640 is primarily positioned on the first side 232 of the hat stringer 200, but the end of the cap segment 646 extends across the center plane 230 to the second side 234. The fourth repair segment 680 is primarily positioned on the second side 234 of the hat stringer 200, but the end of the cover segment 686 extends across the center plane 230 to the first side 232. One of the plurality of fasteners 690 may be as shown in FIG. Fig. 6A Cover segments 616 , 656 , 646 , 686 are shown coupled, which couples first set 600 with second set 602 .

[0105] With the first repair stringer 650, the second repair stringer 660, the third repair stringer 670, and / or the fourth repair stringer 680 of the second group 602 arranged in place and coupled with the base stringer 210, the second group 602 may be considered to repair the second portion of the cap section and the second web section of the base stringer 210. With the first group 600 and the second group 602 coupled together as mentioned above, the first flange section 212 and the second flange section 220 may be considered to be spliced ​​together to complete the splice repair.

[0106] In some other exemplary aspects, the hat stringer can undergo a splice repair using only a single set of repair stringers (such as a set of "relief Z" repair stringers). For example, briefly referring to Figure 6B , a first set 600 of repair stringers is shown for repairing a portion of the cap section 216 and the first web section missing from the cross section of the hat stringer 200. In this example, the base stringer 210 is not damaged or otherwise structurally compromised. Accordingly, in Figure 6B In the example of Fig. 6A The second group 602) is used to complete the splicing repair.

[0107] In still further exemplary aspects, the hat-type stringer may be subjected to full repair, partial repair, or splice repair using at least one relief-break Z-shaped repair stringer and at least one relief-break L-shaped repair stringer.

[0108] In some exemplary aspects, a repair stringer for repairing or repairing a hat stringer is provided according to any of the techniques disclosed herein. The repair stringer may include a web section. The web section has an internal profile that is shaped to match the web portion of the profile of the inner cavity defined by the hat stringer. The repair stringer may also include at least one of a cover section and a flange section extending from the web section. The repair stringer may have a partial cross-section relative to the overall cross-section of the hat stringer. The repair stringer may be installed in multiple possible installation positions along the cross-section of the hat stringer, for example, as viewed along the span direction of the hat stringer. At each of the multiple possible installation positions, the repair stringer is shaped to have an internal profile that matches at least a portion of the profile of the inner cavity defined by the hat stringer. The repair stringer may be formed by one or more laminate layers, such as one or more carbon fiber reinforced polymer (CFRP) laminate layers. In Figure 3A and Figure 3B , Figure 3C , Figure 4A and Figure 4B , Figure 5 and Fig. 6A and Figure 6B Examples of such repair stringers are provided in the examples of FIG.

[0109] In yet other exemplary aspects, a hat-shaped stringer is provided, or more specifically, a repaired or reconditioned hat-shaped stringer. The hat-shaped stringer includes a stringer (such as a base stringer or an existing repair stringer). The hat-shaped stringer also includes at least one repair stringer coupled to the stringer. The repair stringer is coupled to the stringer in an installation position that is one of a plurality of possible installation positions along a cross-section of the hat-shaped stringer, and in each of the plurality of possible installation positions, the repair stringer is formed to have an internal profile that matches at least a portion of a profile of an internal cavity defined by the hat-shaped stringer. The cross-sectional area of ​​the repair stringer is less than the total cross-sectional area of ​​the hat-shaped stringer. Figure 3B , Figure 3C , Figure 4B , Figure 5 and Figure 6B Examples of such repaired hat stringers are provided in the examples of .

[0110] In some aspects, the repaired hat stringers may include at least one relieved Z repair hat stringer and at least one relieved L repair stringer.

[0111] Figure 7 A flow chart of a method 700 of repairing a hat stringer, such as a hat stringer of an aircraft wing, is provided.

[0112] At 702, method 700 includes arranging a repair stringer in an installation position that is one of a plurality of possible installation positions along a cross-section of a hat stringer, and in each of the plurality of possible installation positions, at least a portion of an interior profile of the repair stringer matches at least a portion of a profile of an interior cavity defined by the hat stringer, and wherein a cross-sectional area of ​​the repair stringer viewed along a first direction is less than a total cross-sectional area of ​​the hat stringer viewed along the first direction. In this regard, the repair stringer may be considered to have a partial cross-section relative to the hat stringer. The repair stringer may be arranged relative to the base stringer and / or another stringer, such as another repair stringer.

[0113] In some implementations of the method, in each of a plurality of possible installation positions, the repair stringer has a web section extending parallel to the web section of the stringer. In other words, in each of a plurality of possible installation positions, the repair stringer has a web section extending parallel to the web portion of the contour of the inner cavity. In some other implementations, in each of a plurality of possible installation positions, the repair stringer has at least one section extending parallel to the cover section or the flange section of the stringer. In other words, in each of a plurality of possible installation positions, the repair stringer has at least one section extending parallel to the cover section of the contour of the inner cavity or the flange section of the stringer. In still other implementations, in each of a plurality of possible installation positions, the repair stringer has one section extending parallel to the cover section of the stringer and one section extending parallel to the flange section of the stringer. In other words, in each of the plurality of possible installation positions, the repair stringer has a section extending parallel to the cover portion of the contour of the inner cavity and a section extending parallel to the flange section of the stringer.

[0114] In still other implementations, the hat stringer defines a center plane that divides a first side and a second side of the hat stringer. In such implementations, the plurality of possible mounting positions includes a first possible mounting position in which the repair stringer is primarily positioned on the first side of the hat stringer, and a second possible mounting position in which the repair stringer is primarily positioned on the second side of the hat stringer. In this manner, the repair stringer is shaped to be mountable to either the first side or the second side of the hat stringer, and regardless of whether the repair stringer is mounted in the first possible mounting position or the second possible mounting position, at least a portion of an interior profile of the repair stringer matches at least a portion of a profile of an interior cavity defined by the hat stringer.

[0115] In other implementations, the repair stringer has a cover section, a flange section and a web section, the web section extending between the cover section and the flange section and connecting the cover section and the flange section. For example, the repair stringer can have a "slow-fold Z" cross-section. In this implementation, when the repair stringer is arranged in its installation position, the cover section, the web section and the flange end of the repair stringer extend parallel to the cover section, the web section and the flange section of the stringer, respectively. In other words, when the repair stringer is arranged in its installation position, the cover section, the web section and the flange section of the repair stringer extend parallel to the cover portion of the contour of the inner cavity, the web portion of the contour of the inner cavity and the flange section of the stringer, respectively.

[0116] In some additional implementations, the plurality of possible installation positions includes at least four possible installation positions. In such implementations, the hat stringer may define a center plane that divides a first side and a second side of the hat stringer, and the at least four possible installation positions may include at least two possible installation positions in which the repair stringer is primarily positioned on the first side of the hat stringer and at least two possible installation positions in which the repair stringer is primarily positioned on the second side of the hat stringer.

[0117] In some implementations, at least two possible installation positions where the repair stringer is primarily positioned on a first side of the hat stringer include a first installation position and a second installation position, and in the first installation position, a section of the repair stringer extends parallel to the first flange section of the stringer, and a section of the repair stringer extends parallel to the first web section of the stringer, and in the second installation position, a section of the repair stringer extends parallel to the cap section of the stringer, and a section of the repair stringer extends parallel to the first web section of the stringer. In addition, in such implementations, at least two possible installation positions where the repair stringer is primarily positioned on a second side of the hat stringer include a first installation position and a second installation position, and in the first installation position on the second side, a section of the repair stringer extends parallel to the cap section of the stringer, and a section of the repair stringer extends parallel to the second web section of the stringer, and in the second installation position on the second side, a section of the repair stringer extends parallel to the second flange section of the stringer, and a section of the repair stringer extends parallel to the second web section of the stringer.

[0118] In some other implementations where the plurality of possible mounting positions includes at least four possible mounting positions, the stringer includes a first flange section, a first web section, a cap section, a second web section, and a second flange section, and wherein the plurality of possible mounting positions along a cross section of the hat stringer includes a first mounting position, a second mounting position, a third mounting position, and a fourth mounting position. In the first mounting position, a section of the repair stringer extends parallel to the first flange section of the stringer, and a section of the repair stringer extends parallel to the first web section of the stringer. In the second mounting position, a section of the repair stringer extends parallel to the cap section of the stringer, and a section of the repair stringer extends parallel to the first web section of the stringer. In the third mounting position, a section of the repair stringer extends parallel to the cap section of the stringer, and a section of the repair stringer extends parallel to the second web section of the stringer. In the fourth mounting position, a section of the repair stringer extends parallel to the second flange section of the stringer, and a section of the repair stringer extends parallel to the second web section of the stringer. In this implementation, the first repair stringer may be a first repair stringer and the installation position may be a first installation position, and the method may further include arranging the second repair stringer at the second installation position; arranging the third repair stringer at the third installation position; arranging the fourth repair stringer at the fourth installation position; and coupling the second repair stringer to the stringer at the second installation position, coupling the third repair stringer to the stringer at the third installation position, and coupling the fourth repair stringer to the stringer at the fourth installation position, wherein the first repair stringer is coupled to the stringer.

[0119] In some other implementations, the first repair beam and the second repair beam physically overlap each other, the second repair beam and the third repair beam physically overlap each other, and the third repair beam and the fourth repair beam physically overlap each other (such as in Figure 4A and Figure 4B In yet other implementations, the first repair beam, the second repair beam, the third repair beam, and the fourth repair beam all have the same cross-sectional shape, and wherein the second repair beam is oriented to be vertically and horizontally flipped relative to the first repair beam, the third repair beam is oriented to be vertically flipped relative to the first repair beam, and the fourth repair beam is oriented to be horizontally flipped relative to the first repair beam (such as in Figure 4A and Figure 4B ).

[0120] In some implementations of method 700, the repair stringer may have a "slow-fold Z" cross-sectional shape and may be installed at a plurality of installation positions along the cross-section of the hat stringer, and regardless of its installation position, at least a portion of the interior profile of the repair stringer matches at least a portion of the profile of the interior cavity defined by the hat stringer. For example, the repair stringer may be installed at Figure 3A and Figure 3B The first repair beam 300 is installed at the installation position, Figure 3A and Figure 3B The second repair beam 310 in is installed in the mounting position or some other mounting position. In each of these mounting positions, the inner contour of the repair beam matches at least a portion of the contour of the inner cavity of the hat beam. In some implementations, the repair beam can be installed in at least two possible mounting positions. In some other implementations, the repair beam having a "gentle-fold Z" cross-sectional shape can be installed in multiple possible mounting positions along the cross-section of the hat beam, and in at least two of the possible mounting positions, in different mounting orientations, for example, a first mounting position in which the repair beam is upright is in a first orientation and a second mounting position in which the repair beam has been horizontally flipped relative to the first orientation is in a second orientation. In each of the mounting orientations, at least a portion of the inner contour of the repair beam matches at least a portion of the contour of the inner cavity defined by the hat beam.

[0121] In some other implementations of method 700, the repair stringer may have a "slow-bend L" cross-sectional shape and may be installed at a plurality of installation positions along the cross-section of the hat stringer, and regardless of its installation position, at least a portion of the interior contour of the repair stringer matches at least a portion of the contour of the interior cavity defined by the hat stringer. For example, the repair stringer may be installed at Figure 4A and Figure 4B The first repair beam 400 is installed at the installation position, Figure 4A and Figure 4B The second repair beam 410 is installed at the installation position, Figure 4A and Figure 4B The third repair beam 420 is installed at the installation position, Figure 4A and Figure 4B The fourth repair stringer 430 in FIG. 4 is installed in the mounting position or some other mounting position. In each of these mounting positions, the inner profile of the repair stringer matches at least a portion of the profile of the inner cavity of the hat stringer. In some implementations, the repair stringer can be installed in at least four possible mounting positions.

[0122] In some other implementations, the repair stringer having a "slow-fold L" cross-sectional shape can be installed in a plurality of possible installation positions along the cross-section of the hat stringer, and in at least four possible installation positions, in different installation orientations, for example, a first installation position in which the repair stringer is upright in a first orientation, a second installation position in which the repair stringer is inverted relative to the first orientation in a second orientation, a third installation position in which the repair stringer is upright but horizontally flipped relative to the first orientation in a third orientation, and a fourth installation position in which the repair stringer is inverted and horizontally flipped relative to the first orientation in a fourth orientation. In each of the installation orientations, at least a portion of an interior profile of the repair stringer matches at least a portion of a profile of an interior cavity defined by the hat stringer.

[0123] At 704, method 700 includes coupling the repair stringer to the stringer of the hat stringer at the installation location. For example, the repair stringer may be coupled to the hat stringer in a suitable manner, such as by mechanical fasteners, heat treatment, compression treatment, combinations thereof, and the like.

[0124] In some other implementations, the repair stringer can be a first repair stringer, and the method 700 can also include arranging a second repair stringer in a mounting position along a cross-section of the hat stringer, the second repair stringer being shaped to have an internal profile that matches at least a portion of the profile of the inner cavity. As with the first repair segment, the cross-sectional area of ​​the second repair stringer as viewed along the first direction is less than the total cross-sectional area of ​​the hat stringer as viewed along the first direction. In this regard, the second repair stringer can be considered to have a partial cross-sectional area relative to the hat stringer. In some implementations, the second repair stringer has the same cross-sectional shape as the first repair stringer, for example, as viewed along the first direction.

[0125] In some other implementations, the second repair stringer is arranged so that the cover section of the second repair stringer and the cover section of the first repair stringer physically overlap and both extend parallel to the cover sections of the stringers, or in other words, both extend parallel to the cover portion of the profile of the inner cavity of the hat stringer. In yet another implementation, the first repair stringer has a web section that physically overlaps the first web section of the stringer, and the second repair stringer has a web section that physically overlaps the second web section of the stringer.

[0126] In yet another implementation, the second repair stringer has a flange section extending parallel to but spaced apart from the second flange section of the stringer. In such an implementation, the method 700 may further include placing one or more shims between the second flange section and the flange section of the second repair stringer.

[0127] In implementations where the second repair stringer is arranged along a cross section of the hat stringer, at 704 , the method 700 may further include coupling the second repair stringer to the stringer, such as by mechanical fasteners, heat treatment, compression treatment, combinations thereof, or the like.

[0128] Figure 8 A flow chart of a method 800 of repairing a hat stringer, such as a hat stringer of an aircraft wing, is provided.

[0129] At 802, method 800 includes arranging a first repair stringer along a cross-section of a hat beam, the interior profile of the first repair stringer matching at least a portion of the profile of an inner cavity defined by the hat beam. As an example, the first repair stringer may have a "gentle fold Z" cross-sectional shape. As another example, the first repair stringer may have a "gentle fold L" cross-sectional shape. The first repair stringer may be arranged such that at least a first section thereof is arranged parallel to a web portion of the profile of the inner cavity, and such that a second section thereof is arranged parallel to a cover portion of the profile of the inner cavity, or such that the second section is arranged parallel to a flange section of a base stringer. In some implementations, the first repair stringer may include a third section connected to the second section via the first section. The third section extends parallel to the second section.

[0130] At 804, method 800 includes arranging a second repair stringer along a cross section of the hat stringer, the interior profile of the second repair stringer matching at least a portion of the profile of the inner cavity, the first repair stringer and the second repair stringer being arranged such that a section of the second repair stringer physically overlaps a section of the first repair stringer. As an example, the second repair stringer may have a "relaxed Z" cross-sectional shape. As another example, the second repair stringer may have a "relaxed L" cross-sectional shape. The second repair stringer may be arranged such that at least a first section thereof is arranged parallel to a web portion of the profile of the inner cavity, which web portion may be the same web portion or a different web portion that is aligned parallel to the first section of the first repair stringer. The second section of the second repair stringer may be arranged parallel to a cap portion of the profile of the inner cavity, or such that the second section of the second repair stringer is arranged parallel to a flange section of the base stringer. In some implementations, the second repair stringer may include a third section connected to the second section of the second repair stringer via the first section of the second repair stringer. The third section of the second repair beam extends parallel to the second section of the second repair beam.

[0131] Furthermore, in some implementations, the first repair stringer and the second repair stringer are arranged such that a section of the second repair stringer physically overlaps a section of the first repair stringer along the web section of the hat stringer. Figure 4AAn example of this is shown in , where the web section 414 of the second repair stringer 410 physically overlaps the web section 404 of the first repair stringer 400 along the web section of the hat stringer 200). In still other implementations, the first repair stringer and the second repair stringer are arranged such that a section of the second repair stringer physically overlaps a section of the first repair stringer along the cap section of the hat stringer ( Figure 3B An example of this is shown in , where the cover section 316 of the second repair beam 310 physically overlaps the cover section 306 of the first repair beam 300 along the cover section of the hat beam 200 ).

[0132] At 806, method 800 includes coupling a first repair stringer and a second repair stringer to a stringer of the hat stringer. For example, the repair stringer may be coupled to the base stringer in a suitable manner, such as by mechanical fasteners (such as in Figure 3B , Figure 3C , Figure 4B ), heat treatment, compression treatment, combinations thereof, etc.

[0133] Fig. 9 A flow chart of a method 900 of performing a splice repair of a hat stringer, such as a hat stringer of an aircraft wing, is provided.

[0134] At 902, method 900 includes arranging a first repair stringer such that a section of the first repair stringer is positioned in or adjacent to a plane in which a missing section of a base stringer was previously positioned. Fig. 6A , a first repair stringer 610 is shown arranged so that its web section 614 is positioned in or adjacent to the plane 208 in which the missing section 206 of the base stringer 210 was previously positioned. Figure 6B Another example is provided.In some implementations, the missing section can include one or more web sections, cap sections, or a combination thereof of a base stringer.

[0135] At 904, method 900 includes arranging the second repair stringer and the third repair stringer such that a section of the second repair stringer and a section of the third repair stringer sandwich a section of the first repair stringer positioned within or adjacent to the plane. Fig. 6A , the second and third repair stringers 620, 630 are shown arranged such that their respective web sections 624, 634 sandwich the web section 614 of the first repair stringer 610 that is positioned within or adjacent to the plane 208. Figure 6B Another example is provided.

[0136] At 906, method 900 includes arranging a fourth repair stringer such that a segment of the fourth repair stringer and the first repair stringer sandwich the second repair stringer. Fig. 6A , the fourth repair stringer 640 is shown arranged such that its web section 644 and the web section 614 of the first repair stringer 610 sandwich the web section 624 of the second repair section 620 . Figure 6B Another example is provided.

[0137] At 908, method 900 includes coupling a first repair stringer, a second repair stringer, a third repair stringer, and a fourth repair stringer to the base stringer. For example, the repair stringer may be coupled to the base stringer in a suitable manner, such as by mechanical fasteners (such as in Fig. 6A In the example or in Figure 6B ), heat treatment, compression treatment, combinations thereof, etc.

[0138] In some implementations, the first repair stringer, the second repair stringer, the third repair stringer, and the fourth repair stringer are all shaped to have an interior profile that matches at least a portion of a profile of an interior cavity defined by the hat stringer. In some other implementations, the first repair stringer, the second repair stringer, the third repair stringer, and the fourth repair stringer all have the same cross-sectional shape as one another.

[0139] In some other implementations, the second repair stringer and the third repair stringer have the same installation orientation, and the first repair stringer and the fourth repair stringer have the same installation orientation. Fig. 6A In the example of , the second repair beam 620 and the third repair beam 630 have the same installation orientation, and the first repair beam 610 and the fourth repair beam 640 have the same installation orientation. Fig. 6A In the example of FIG. 6A , the second repair beam 620 and the third repair beam 630 are oriented to be flipped vertically and horizontally relative to the first repair beam 610 and the fourth repair beam 640 .

[0140] In some implementations, the missing section includes a first web section, a cap section, and a second web section of the base stringer. In such implementations, the first repair stringer, the second repair stringer, the third repair stringer, and the fourth repair stringer form a first group of repair stringers coupled to the base stringer to repair the first web section and the first portion of the cap section of the base stringer. In such implementations, the method 900 may also include: arranging a second group of repair stringers, which may include the first repair stringer, the second repair stringer, the third repair stringer, and the fourth repair stringer; and coupling the second group of repair stringers to the base stringer to repair the second web section and the second portion of the cap section of the base stringer. Fig. 6AAn example of a first set of repair stringers and a second set of repair stringers being used to splice a damaged base stringer is shown in FIG.

Claims

1. A method (700) for repairing a hat stringer, comprising: Arranging (702) a repair stringer (300, 400) in an installation position, the installation position being one of a plurality of possible installation positions along a cross section of the hat stringer (200), and in each of the plurality of possible installation positions, at least a portion of an interior profile (308) of the repair stringer (300) matches at least a portion of a profile (224) of an interior cavity (222) defined by the hat stringer (200), and wherein a cross-sectional area of ​​the repair stringer (300) viewed along a first direction (D1) is less than a total cross-sectional area of ​​the hat stringer (200) viewed along the first direction (D1); and At the installation location, the repair stringer (300) is coupled (704) to the stringer (210) of the hat stringer (200).

2. The method (700) according to claim 1, wherein: In each possible installation position of the plurality of possible installation positions, the repair stringer (300) has a web section (304) extending parallel to a web portion (224A) of the profile (224) of the inner cavity (222).

3. The method (700) according to claim 2, wherein: In each of the plurality of possible installation positions, the repair beam (300) has at least one section (306, 302) extending parallel to a cover portion (224B) of the inner cavity (222) or a flange section (212) of the beam (210).

4. The method (700) of claim 1, wherein: The hat-type beam (200) defines a center plane (230) dividing a first side (232) and a second side (234) of the hat-type beam (200), and wherein the plurality of possible installation positions include a first possible installation position and a second possible installation position, in which the repair beam (300) is mainly positioned on the first side (232) of the hat-type beam (200), and in which the repair beam (300) is mainly positioned on the second side (234) of the hat-type beam (200).

5. The method (700) of claim 1, wherein: The repair beam (300) comprises a cover section (306), a flange section (302) and a web section (304), wherein the web section (304) extends between the cover section (306) and the flange section (302) and connects the cover section (306) and the flange section (302), and wherein, when the repair beam (300) is arranged in the installation position, the cover section (306) of the repair beam (300) extends parallel to the cover section (216) of the beam (210), the web section (304) of the repair beam extends parallel to the web section (214) of the beam (210), and the flange section (302) of the repair beam extends parallel to the flange section (212) of the beam (210).

6. The method (700) of claim 1, wherein: The repair stringer (300) is a first repair stringer (300), and wherein the method (700) further comprises: A second repair beam (310) is arranged in an installation position along a cross section of the hat beam (200), the second repair beam (310) being shaped to have an internal profile (318) matching at least a portion of the profile of the inner cavity (222), and wherein a cover section (316) of the second repair beam (310) and a cover section (306) of the first repair beam (300) physically overlap each other and both extend parallel to a cover portion (224B) of the profile (224) of the inner cavity (222).

7. The method (700) according to claim 6, wherein: The first repair stringer (300) has a web section (304) that physically overlaps a first web section (214) of the stringer (210), and the second repair stringer (310) has a web section (314) that physically overlaps a second web section (218) of the stringer (210).

8. The method (700) according to claim 7, wherein: The second repair stringer (310) has a flange section (312) extending parallel to but spaced apart from the second flange section (220) of the stringer (210), and wherein the method (700) further comprises: One or more shims (320) are disposed between the second flange section (220) and the flange section (312) of the second repair stringer (310).

9. The method (700) according to claim 8, wherein: The second repair beam (310) has the same cross-sectional shape as the first repair beam (300) when viewed along the first direction (D1).

10. The method (700) of claim 1, further comprising: Arranging a second repair stringer (420) at a mounting position along a cross section of the hat stringer (200), the second repair stringer (420) being shaped to have an inner profile (418) matching at least a portion of the profile (224) of the inner cavity (222); A third repair stringer (450) is arranged at an installation position along the cross section of the hat stringer (200), the third repair stringer (450) having a first web section (454), a cap section (456) and a second web section (458), and The first web section (454) is connected to the repair stringer (400), the cover section (456) is connected to the stringer (210), and the second web section (458) is connected to the second repair stringer (420).

11. The method (700) of claim 1, wherein: The hat beam (200) defines a center plane (230) dividing a first side (232) and a second side (234) of the hat beam (200), and the plurality of possible installation positions include at least four possible installation positions, and wherein the at least four possible installation positions include: at least two possible installation positions in which the repair beam can be primarily positioned on the first side (232) of the hat beam (200); and at least two possible installation positions in which the repair beam can be primarily positioned on the second side (234) of the hat beam (200).

12. The method (700) of claim 11, wherein the at least two possible installation positions in which the repair stringer can be primarily positioned on the first side (232) of the hat stringer (200) include a first installation position and a second installation position, and In the first installed position, a section of the repair stringer (300) extends parallel to the first flange section (212) of the stringer (210), and a section (304) of the repair stringer (300) extends parallel to the first web section (214) of the stringer (210), and In the second installation position, a section of the repair stringer (300) extends parallel to the cover section (216) of the stringer (210), and a section (304) of the repair stringer (300) extends parallel to the first web section (214) of the stringer (210).

13. The method (700) of claim 12, wherein the at least two possible installation positions in which the repair stringer is primarily positioned on the second side (234) of the hat stringer (200) include a first installation position and a second installation position, and In the first installation position, a section of the repair stringer (300) extends parallel to the cover section (216) of the stringer (210), and a section (314) of the repair stringer (300) extends parallel to the second web section (218) of the stringer (210), and In the second installed position, a section (312) of the repair stringer (300) extends parallel to the second flange section (220) of the stringer (210), and a section (314) of the repair stringer (300) extends parallel to the second web section (218) of the stringer (210).

14. The method (700) of claim 1, wherein: The stringer (210) comprises a first flange section (212), a first web section (214), a cover section (216), a second web section (218) and a second flange section (220), wherein the plurality of possible installation positions along a cross section of the hat-type stringer (200) comprises a first installation position, a second installation position, a third installation position and a fourth installation position, and: In the first installation position, a section (402) of the repair stringer (400) extends parallel to the first flange section (212) of the stringer (210), and a section (404) of the repair stringer (400) extends parallel to the first web section (214) of the stringer (210), In the second installation position, a section (402) of the repair stringer (400) extends parallel to the cover section (216) of the stringer (210), and a section (404) of the repair stringer (300) extends parallel to the first web section (214) of the stringer (210), In the third installation position, a section (402) of the repair stringer (400) extends parallel to the cover section (216) of the stringer (210), and a section (402) of the repair stringer (400) extends parallel to the second web section (218) of the stringer (210), and In the fourth installation position, a section (402) of the repair stringer (400) extends parallel to the second flange section (220) of the stringer (210), and a section of the repair stringer (400) extends parallel to the second web section (218) of the stringer (210).

15. The method (700) of claim 14, wherein: The repair stringer (400) is a first repair stringer, and the installation location is the first installation location, and wherein the method (700) further comprises: Arranging a second repair stringer (410) at the second installation position; Arranging a third repair stringer (420) at the third installation position; placing a fourth repair stringer (430) in the fourth installation position; and The second repair stringer (410) is coupled to the stringer (210) in the second installation position, the third repair stringer (420) is coupled to the stringer in the third installation position and the fourth repair stringer (430) is coupled to the stringer in the fourth installation position, wherein in the first installation position the first repair stringer (410) is coupled to the stringer (210).

16. The method (700) of claim 15, wherein: The first repair beam (400) and the second repair beam (410) physically overlap each other, the second repair beam (410) and the third repair beam (420) physically overlap each other, and the third repair beam (420) and the fourth repair beam (430) physically overlap each other.

17. The method (700) of claim 16, wherein: The first repair beam (400), the second repair beam (410), the third repair beam (420) and the fourth repair beam (430) all have the same cross-sectional shape observed along the first direction (D1), and wherein the second repair beam (410) is oriented to be vertically and horizontally flipped relative to the first repair beam (400), the third repair beam (420) is oriented to be vertically flipped relative to the first repair beam (400), and the fourth repair beam (430) is oriented to be horizontally flipped relative to the first repair beam (400).

18. The method (700) of claim 1, wherein: The repair stringer (300) is a first repair stringer (610), and wherein the first repair stringer (610) is arranged such that a section (614) of the first repair stringer (610) is positioned in or adjacent to a plane in which the missing section (206) of the stringer (210) was previously positioned, and wherein the method (700) further comprises: Arranging a second repair beam (620) and a third repair beam (630) such that a section (624) of the second repair beam (620) and a section (634) of the third repair beam (630) sandwich a section (614) of the first repair beam (610) located in or adjacent to the plane; Arranging a fourth repair stringer (640) such that a section (644) of the fourth repair stringer (640) and the first repair stringer (610) sandwich the second repair stringer (620); and The first repair beam (610), the second repair beam (620), the third repair beam (630), and the fourth repair beam (640) are coupled to each other and to the beam (210).

19. A method (800) for repairing a hat stringer, comprising: Arranging a first repair stringer (300) along a cross section of the hat stringer (200), wherein an inner profile (308) of the first repair stringer (300) matches at least a portion of a profile (224) of an inner cavity (222) defined by the hat stringer (200); a second repair beam (310) arranged along a cross section of the hat beam (200), an inner profile (318) of the second repair beam (310) matching at least a portion of the profile (224) of the inner cavity (222), the first repair beam (300) and the second repair beam (310) being arranged such that a section (316) of the second repair beam (310) physically overlaps a section (306) of the first repair beam (300); and The first repair beam (300) and the second repair beam (310) are coupled to the beam (210) of the hat beam (200).

20. A repair stringer (300, 400), comprising: a web section (304) having an internal profile (308) shaped to match a web portion (224A) of a profile (224) of an internal cavity (222) defined by a hat stringer (200); and at least one of a cover section (306) and a flange section (302) extending from the web section (304), and The repair beam (300) has a partial cross-section relative to the total cross-section of the hat beam (200).

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