Composite aerodynamic structure

Patent metadata

Field	Value
Publication number	US-11292578-B2
Application number	US-201916684118-A
Country	US
Kind code	B2
Filing date	Nov 14, 2019
Priority date	Nov 14, 2019
Publication date	Apr 5, 2022
Grant date	Apr 5, 2022

Abstract

A monolithic skin for an aerodynamic structure is provided. The skin comprises a root end defining a root opening; a tip end opposite to the root end; a trailing-edge portion defining a slot opening extending from the root opening toward the tip end; a leading-edge portion extending spanwise from the root end to the tip end; and a middle portion extending between the trailing edge and the leading-edge portion and at least partially defining an open slot in fluid communication with the slot opening and root opening. The middle portion comprises an interior surface facing the open slot that is graded so that the middle portion decreases in thickness spanwise toward the root end. The middle portion also comprises a first integrated spar section extending from the interior surface to the tip end.

First claim

Having thus described various embodiments of the invention, what is claimed as new and desired to be protected by Letters Patent includes the following:

1. A method of forming a monolithic skin of an aerodynamic structure with a leading edge and a trailing edge, the method comprising:
positioning a plurality of plies on a tool to form a skin comprising a first integrated spar section extending spanwise between a root end and a tip end of the skin;
curing the skin;
flexing the skin so that a trailing-edge opening defined by a trailing-edge portion of the skin is expanded; and
removing the skin from the tool by pulling the tool chordwise out of the trailing-edge opening of the skin.

2. The method of claim 1 , wherein the step of removing the tool includes pulling the tool spanwise out of a root opening defined by the root end of the skin.

3. The method of claim 1 , further comprising positioning a caul over an exterior surface of the skin before curing the skin in an autoclave.

4. The method of claim 1 , further comprising inserting a tab of a trailing edge panel into the trailing-edge opening and bonding the tab to inside surfaces of the skin.

5. The method of claim 1 , wherein the tool comprises a graded surface that imparts a complementary graded surface extending from an end of the first integrated spar section to the root end of the skin so that the skin decreases in thickness spanwise toward the root end from the end of the first integrated spar section.

Assignees

• Spirit Aerosys Inc

Inventors

• Sellmeyer Scott
• Bergmann Blaise Francis
• Wiley Darin Clay
• Kornfeld Roger Edmund
• Chappelle Walter A
• Heitmann Aaron Rae

Classifications

• B64C3/185

  Spars · CPC title

• B64C3/26 Primary

  Construction, shape, or attachment of separate skins, e.g. panels · CPC title

• B64C3/14

  Aerofoil profile · CPC title

• B64C3/20 Primary

  Integral or sandwich constructions · CPC title

• B64C3/54

  Varying in area · CPC title