Stamped aircraft fairing

Abstract

An aircraft antenna assembly for an electronically steered antenna, the aircraft antenna assembly including a formed aluminum fairing integrated with the electronically steered antenna, wherein the fairing comprises an integrated skirt and top surface framing the electronically steered antenna and an adapter plate connecting the fairing to the aircraft.

Description

AC-CSC-110-PCTSTAMPED AIRCRAFT FAIRING BACKGROUND OF THE INVENTIONField of the Invention

[0001] This invention relates generally to a mounting system for external aircraft electronics and / or hardware, such as an antenna.Description of Prior Art

[0002] Satellite technology used by commercial and private aircraft has improved dramatically over the years. Legacy geosynchronous orbit satellites suffer from high latency due to the distances involved, have limited bandwidth, and suffer from signal quality issues at high latitudes and around the equator. Newer low Earth orbit satellites have low latency due to their proximity to Earth, maintain high bandwidth in less densely populated areas and have high connectivity even in traditionally difficult areas like high latitudes and around the equator.

[0003] As a result of changes in satellite technology, aircraft antenna technology has also changed. Legacy antennae were generally mechanical point and track antenna capable of operating at low power levels but required larger enclosures (radomes) for mounting. New electronically steered antenna or array (ESA) are ideally compatible with low Earth orbit satellites and are capable of operation at high latitudes and around the equator. In addition, ESAs include a lower profile than legacy antennas and thus can be mounted in a more streamlined enclosure. One perceived downside of ESAs, however, is that they require higher operating power levels thereby producing a large amount of heat. Current standards permit up to 2000W of power to the antenna. This power is largely dissipated as heat.

[0004] Traditional mounting methods for all forms of on-aircraft SATCOM antennae have evolved from bulky radomes to more streamlined outside antenna equipment (OAE). Recent OAE solutions include composite skirts with aluminum adapter plates to mount the antenna to the aircraft. However, such solutions are expensive and do not dissipate heat sufficiently for modem ESA requirements.

[0005] A need therefore exists for a mounting system that is cost efficient, sufficiently strong, low profile, and capable of efficient heat transfer.SUMMARY OF THE INVENTION

[0006] The invention generally relates to a fairing for electronics and / or hardware such as antennae, communications systems, etc. A preferred aircraft antenna assembly for an antenna, preferably an electronically steered antenna, includes a formed sheet metal fairing integrated structurally and / or thermally with the electronically steered antenna. The sheet metalAC-CSC-110-PCTfairing is preferably stamped or hydroformed and preferably is formed of aluminum although other formed sheet metal may be used. Aluminum is particularly beneficial for its heat conducting properties which are useful in the high heat environment created by electronically steered antenna.

[0007] The fairing preferably comprises an integrated skirt and top surface framing the electronically steered antenna. The aircraft antenna assembly preferably further includes an adapter plate connecting the fairing to the aircraft.

[0008] In one embodiment of the aircraft antenna assembly, the fairing, the electronically steered antenna and the adapter plate are all in physical contact with one another. As a result of such contact, heat transfer is greatly enhanced.

[0009] In one embodiment, the fairing is formed in two engageable halves. In addition, decompression vents are preferably integrally formed in the fairing, such as at junctures of the two engageable halves of the fairing, in that embodiment.

[0010] The aircraft antenna assembly is preferably constructed so that the electronically steered antenna nests within the adapter plate and the fairing is placed over both the adapter plate and the electronically steered antenna. In this arrangement, a top surface of the fairing is generally flush with a top surface of the electronically steered antenna.

[0011] A method of manufacture of a fairing for an aircraft fuselage preferably includes providing sheet metal, such as aluminum, to a fixture and then forming the sheet metal in the fixture at an annealed state. The stamped sheet metal is then released from the fixture then heat treated and cut into a finished fairing. The subject method may additionally include intermediate steps of stress relieving and restamping in order to maintain tolerances.

[0012] According to one alternative embodiment, the fairing may or not be of stamped construction but the antenna chassis is extended along the fairing for the purpose of exposing it to the external environment for heat dissipation. Such an extended arrangement may include additional heat transfer features such as ridges to lower the energy absorbed due to solar radiance - as radiance is absorbed more efficiently at a perpendicular angle. Other angles reflect radiance and thus wave shape extensions are very efficient at reflecting radiance. In such an embodiment this extended chassis or “wings” extend from on or within the antenna chassis which are exposed outside the fairing.

[0013] In another embodiment, one or more intermediate adapters are positioned between the adapter plate and the ESA to accommodate a range of ESA designs.

[0014] Other objects and advantages will be apparent to those skilled in the art from the following detailed description taken in conjunction with the appended claims and drawings.AC-CSC-110-PCTBRIEF DESCRIPTION OF THE DRAWINGS

[0015] Fig. 1 shows a front perspective view of an aircraft antenna assembly according to one embodiment of the invention;Fig. 2 shows a rear perspective view of an aircraft antenna assembly according to one embodiment of the invention;Fig. 3 shows a side perspective exploded view of the aircraft antenna assembly shown in Fig. 2;Fig. 4 shows an opposite side perspective exploded view of the aircraft antenna assembly shown in Fig. 2;Fig. 5 shows a front perspective view of an aircraft antenna assembly according to one embodiment of the invention;Fig. 6 shows a thermal signature of a portion of an aircraft antenna assembly according to one embodiment of the invention;Fig. 7 shows a thermal signature of a portion of an aircraft assembly according to one embodiment of the invention using a composite fairing;Fig. 8 shows a legacy composite antenna assembly including upper and lower fairings;Fig. 9 shows one embodiment of a fairing having extended portions from the antenna into and across each end of the fairing;Fig. 10 shows a front perspective view of an aircraft antenna assembly having an additional adapter according to an additional embodiment of the invention;Fig. 11 shows a side perspective exploded view of the aircraft antenna assembly shown in Fig. 10;Fig. 12 shows a front perspective exploded view of the aircraft antenna assembly shown in Fig. 10;Fig. 13 shows a top view of the aircraft antenna assembly shown in Fig. 10; and Fig. 14 shows a front perspective view of an aircraft antenna assembly shown in Fig. 10.DETAILED DESCRIPTION OF THE INVENTION

[0016] The present invention provides a fairing 20 for electronics and / or hardware such as antennae for an aircraft fuselage 10. As shown in Figs. 1-6, an aircraft antenna assembly for an antenna, such as an electronically steered antenna (also referred to as an “ESA” herein), preferably includes a formed sheet metal fairing 20 integrated structurally and / or thermallyAC-CSC-110-PCTwith the electronically steered antenna 50. As described herein, the sheet metal fairing 20 is preferably formed by stamping or hydroforming or other processes for forming sheet metal.

[0017] The sheet metal preferably comprises aluminum which is beneficial for its heat conducting properties. Other metals may alternatively be employed provided they exhibit similar weight, strength, and heat conduction as aluminum.

[0018] As shown in the figures, the fairing 20 preferably comprises a unitary skirt 30 and top surface 40 framing the electronically steered antenna 50. In a preferred embodiment, the top surface of the fairing 40 is generally flush with a top surface 55 of the electronically steered antenna 50.

[0019] Completing a preferred assembly is an adapter plate 70 connecting the fairing 20 to the aircraft fuselage 10. The adapter plate 70 is preferably likewise constructed of aluminum thereby enhancing heat transfer from the ESA 50.

[0020] The electronically steered antenna 50, the fairing 20, and the adapter plate 70 are all preferably in physical contact with one another. By mating the ESA 50 in physical engagement with the fairing 20, the waste heat from the ESA 50 is conducted from the ESA 50 into the fairing 20 where the fairing 20 becomes a functional part of the heat dissipation path. Fig. 6 shows one example of the thermal signature of a preferred assembly having an upward and outward heat path. Fig. 7 shows an embodiment using a composite fairing that was found to trap heat and / or direct heat downward. The subject invention is capable of substantially lowering the under-fairing air temperature over traditional fiberglass or composite options. As such, the fairing according to this invention is useful as a functional part of a heat management strategy. Further, the design of the fairing 20 may be optimized to intentionally route heat from the ESA 50 to the fairing 20.

[0021] As best shown in Figs. 3 and 4, the electronically steered antenna 50 nests within the adapter plate 70 and the fairing 20 is placed over both the adapter plate 70 and the electronically steered antenna 50. A seal 80 is generally positioned between the fairing 20 and the aircraft fuselage as shown in Fig. 1 and 2.

[0022] One or more decompression vents 45 may be integrally formed in the fairing 20 as shown in Figs. 1 and 2. The decompression vents 45 preferably act to release pressure from the aircraft antenna assembly in the event of a fuselage decompression event.

[0023] According to one embodiment of the invention, as best shown in Fig. 5, the fairing 20 is formed in two engageable halves 60, 65. These halves 60, 65 may likewise be stamped or hydroformed from sheet metal creating the benefits described above. In such embodiment, the decompression vents 45 may be integrally formed at junctures of the twoAC-CSC-110-PCTengageable halves 60, 65 of the fairing 20. Alternative embodiments may include three or more assembled components resulting in the final fairing assembly.

[0024] The subject fairing 20 preferably combines the upper aerodynamic fairing aspects of a traditional radome and the lower aerodynamic fairing aspects of a traditional skirt used to mate the fairing with the aircraft. Such an arrangement is shown by illustration in Fig.8 wherein an upper fairing / radome is mated to a lower fairing / skirt to enclose the antenna without regard to structural and / or thermal integration. The subject fairing 20 therefore carries structural loads such as aerodynamic, fuselage bending, vibration, and bird strike loads, as well as being tasked with participating in the thermal management strategy for ESAs 50. Therefore, the subject fairing is structural and functional in ways that older skirts were not.

[0025] Because of the narrow and relatively short structure of the preferred assembly, no composite parts are utilized thereby improving heat transfer. The subject technology is preferably scalable to allow for a larger ESA to be utilized

[0026] From a thermal perspective, thin metal such as employed in the subject invention will radiate heat better. Thicker metal, such as conventional machined components, are prone to “heat soak,” whereas, a thinner, sheet metal fairing should improve the convective heat transfer to the ambient environment particularly for the heat generated by ESA antennas. Heat Soak will be especially critical for bulkier machined adapter plates at the gate where the thermal transfer coefficient is significantly less than in-flight.

[0027] As best shown in Fig. 5, the subject aircraft antenna assembly may further include a plurality of fasteners attached between the adapter plate and aircraft fuselage. The fasteners may comprise nuts and bolts, rivets, spinwheels, fast leveling mounting lugs, and / or other appropriate connectors for maintaining the two components into a fixed position with each other.

[0028] A method of manufacture of a fairing 20 for an aircraft fuselage preferably includes providing sheet metal, such as aluminum, to a fixture and then stamping the sheet metal in the fixture at an annealed state. The stamped sheet metal is then released from the fixture then heat treated and cut, such as in a 5-axis CNC or mill, into a finished fairing. The subject method may additionally include intermediate steps of stress relieving and restamping in order to maintain tolerances.

[0029] An alternative embodiment is shown in Fig. 9. Fig. 9 shows an antenna 50 having extended portions 90 or “wings” that extend directly from the antenna 50. Fig. 9 additionally shows the wings 90 extending at least partially across an upper exposed surfaceAC-CSC-110-PCTconstruction as described herein. However, the antenna 50 chassis extends, with integrated tiles or other physical extensions, outside of the fairing 20 for the purpose of exposing it to the external environment for heat dissipation. Such an extended arrangement may be smooth or may include additional heat transfer features such as ridges, as shown in Fig. 9, to lower the energy absorbed due to solar radiance - as radiance is absorbed more efficiently at a perpendicular angle. Other angles reflect radiance and thus wave shape extensions are very efficient at reflecting radiance. In such an embodiment this extended chassis or “wings” 90 extend from on or within the antenna chassis which are exposed outside the fairing 20.

[0030] Figs. 10-14 show additional embodiments of the subject invention wherein a flexible OAE can support multiple ESA configurations, sizes, and designs. According to a preferred embodiment, one or more additional adapters 175 may be positioned between the adapter plate 170 and the ESA 150. A fairing 120 may then be placed over the ESA 150 and the adapter plate 170 as described in more detail above. This embodiment permits integration of a variety of ESAs into the existing adapter plate 170 structure.

[0031] Traditionally, each time another antenna design is developed, the whole aircraft structure (adapter plate, radome, antenna, etc.) is removed. ESA antennas permit a more uniform approach but still result in multiple adapter plate and fairing designs. To eliminate this potential, the additional adapter 175 may be placed into the intermediate space between the ESA 150 and the adapter plate 175 to ensure a tight and aerodynamic fit.

[0032] As ESA antennas 150 secure along a perimeter of the traditional adapter plate 170 with fasteners, the antenna chassis will need to take some structural load. An aim of the subject invention is to have that load be a low percentage, but it will be distinctly above zero as the fuselage 110 bends so the adapter plate 170 bends, and thus the antenna chassis will bend. This means that the additional adapter 175 will constitute a structural portion of the load path. It would carry aerodynamic, inertial, bending, and thermal loads.

[0033] The invention illustratively disclosed herein suitably may be practiced in the absence of any element, part, step, component, or ingredient which is not specifically disclosed herein.

[0034] While in the foregoing detailed description this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purposes of illustration, it will be apparent to those skilled in the art that the invention is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.

Claims

AC-CSC-110-PCTWhat is claimed is:

1. An aircraft antenna assembly for an electronically steered antenna, the aircraft antenna assembly comprising:a formed sheet metal fairing integrated structurally and thermally with the electronically steered antenna.

2. The aircraft antenna assembly of Claim 1 wherein the sheet metal fairing is one of stamped and hydroformed.

3. The aircraft antenna assembly of Claim 1 wherein the sheet metal comprises aluminum.

4. The aircraft antenna assembly of Claim 1 wherein the fairing comprises a unitary skirt and top surface framing the electronically steered antenna.

5. The aircraft antenna assembly of Claim 4 wherein the fairing is formed in two engageable halves.

6. The aircraft antenna assembly of Claim 5 further comprising decompression vents integrally formed at junctures of the two engageable halves of the fairing.

7. The aircraft antenna assembly of Claim 4 further comprising at least one decompression vent integrally formed in the fairing.

8. The aircraft antenna assembly of Claim 1 further comprising an adapter plate connecting the fairing to the aircraft.

9. The aircraft antenna assembly of Claim 8 wherein the fairing, the electronically steered antenna and the adapter plate are all in physical contact with one another.

10. The aircraft antenna assembly of Claim 8 wherein the electronically steered antenna nests within the adapter plate and the fairing is placed over both the adapter plate and the electronically steered antenna.AC-CSC-110-PCT11. The aircraft antenna assembly of Claim 8 further comprising an additional adapter positioned between the electronically steered antenna and the adapter plate.

12. The aircraft antenna assembly of Claim 1 wherein a top surface of the fairing is generally flush with a top surface of the electronically steered antenna.

13. The aircraft antenna assembly of Claim 12 wherein one or more extensions extend from the top surface of the electronically steered antenna across the top surface of the fairing.

14. The aircraft antenna assembly of Claim 1, wherein the antenna includes a chassis extension that extends from the antenna across at least a portion of a top surface of the fairing.

15. An aircraft antenna assembly for an electronically steered antenna, the aircraft antenna assembly comprising:a formed aluminum fairing integrated with the electronically steered antenna, wherein the fairing comprises an integrated skirt and top surface framing the electronically steered antenna; andan adapter plate connecting the fairing to the aircraft, wherein the fairing, the electronically steered antenna and the adapter plate are all in physical contact with one another.

16. The aircraft antenna assembly of Claim 15 wherein the aluminum fairing is one of stamped and hydroformed.

17. The aircraft antenna assembly of Claim 15 wherein a top surface of the fairing is generally flush with a top surface of the electronically steered antenna.

18. The aircraft antenna assembly of Claim 15 further comprising at least one decompression vent integrally formed in the fairing.

19. The aircraft antenna assembly of Claim 15 wherein the adapter plate is aluminum.AC-CSC-110-PCT20. The aircraft antenna assembly of Claim 15 wherein the formed sheet metal fairing is integrated structurally and / or thermally with the electronically steered antenna.

21. A method of manufacture of a fairing for an aircraft fuselage comprising:providing sheet metal to a fixture;stamping the sheet metal in the fixture at an annealed state;releasing the stamped sheet metal from the fixture; andcutting the stamped sheet metal into a finished fairing.

22. The method of Claim 21 further comprising:stress relieving and restamping the stamped sheet metal; andheat treating the stamped sheet metal.

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