WO2014065718A1 - Structure intégrée incurvée et amélioration de la résistance d'ailette - Google Patents

Structure intégrée incurvée et amélioration de la résistance d'ailette Download PDF

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Publication number
WO2014065718A1
WO2014065718A1 PCT/SE2012/051126 SE2012051126W WO2014065718A1 WO 2014065718 A1 WO2014065718 A1 WO 2014065718A1 SE 2012051126 W SE2012051126 W SE 2012051126W WO 2014065718 A1 WO2014065718 A1 WO 2014065718A1
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WO
WIPO (PCT)
Prior art keywords
transition region
skin
winglet
transverse
curved
Prior art date
Application number
PCT/SE2012/051126
Other languages
English (en)
Inventor
Pontus Nordin
Anders RYDBOM
Tomas VÅNGELL
Original Assignee
Saab Ab
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Saab Ab filed Critical Saab Ab
Priority to EP12887291.8A priority Critical patent/EP2909009A4/fr
Priority to PCT/SE2012/051126 priority patent/WO2014065718A1/fr
Publication of WO2014065718A1 publication Critical patent/WO2014065718A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
    • B29C70/14—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat oriented
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/12—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by the relative arrangement of fibres or filaments of different layers, e.g. the fibres or filaments being parallel or perpendicular to each other
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64C—AEROPLANES; HELICOPTERS
    • B64C23/00—Influencing air flow over aircraft surfaces, not otherwise provided for
    • B64C23/06—Influencing air flow over aircraft surfaces, not otherwise provided for by generating vortices
    • B64C23/065—Influencing air flow over aircraft surfaces, not otherwise provided for by generating vortices at the wing tips
    • B64C23/069—Influencing air flow over aircraft surfaces, not otherwise provided for by generating vortices at the wing tips using one or more wing tip airfoil devices, e.g. winglets, splines, wing tip fences or raked wingtips
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3076—Aircrafts
    • B29L2031/3085—Wings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/558—Impact strength, toughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T50/00—Aeronautics or air transport
    • Y02T50/10—Drag reduction

Definitions

  • the present invention relates to structurally integrated curved structures according to the preamble of claim 1 and a method of manufacture of the structure according to claim 1 1 .
  • the invention relates to the aircraft industry and to aircraft maintenance engineering.
  • the invention is not limited thereto, but can be used also in automotive engineering, trains, wind power blades etc.
  • Bending moments are present in several curved structures of an aircraft during flight.
  • One type of curved structure is a winglet having fiber reinforced composite skins.
  • the region has to be reinforced by thicker composite laminate, by additional substructures etc.
  • There are different types of winglets such as retrofit winglets, wingtip fences, blended winglets, raked wingtips etc.
  • the main geometrical parameters are the height, the taper ratio and the dihedral angle. If the dihedral angle is near constant, the winglet is almost planar and the transition region between the wing and the winglet root is curved.
  • Blended winglets have a certain degree of sweep related to the rest of the wing.
  • Raked wingtips comprise a higher degree of sweep and can be described as integrated wingtip extensions.
  • the winglets may be attached to the wing tip resulting in relatively sharp corners having a curvature of small radii.
  • a common purpose of the major parts of winglets is to reduce the induced drag. In such way fuel can be saved.
  • the winglet function is to relocate the wing tip vortex of the wing further outboard.
  • winglets are disclosed in for example US2010/0019094, US 5407153, GB 2475523, US 2010/0155541 , US 5 348 253, US 1095952.
  • GB 2475523 discloses a first skin, a second skin, an intermediate structure or substructure having contact portions connected to the inner surface of the skins. Interconnecting webs are integral arranged with the intermediate structure and extend between the inner surfaces of the skins.
  • GB 2475523 also discloses a method that separately forms the first skin, the second skin, the intermediate structure from composite materials.
  • the skins and structure are co-cured in one cure step.
  • the method comprises steps of stacking sheets of pre-impregnated fibers (so called pre-pregs) over mandrels and a second tool, the sheets have sections overlapping and forming the intermediate structure and the contact portion has a thicker portion.
  • the substructure or ribs are formed by laying down a stack of six pre-impregnated carbon fiber sheets over aluminium alloy mandrels and closed by a lower skin tool in predetermined
  • the sheets can be laid down by an automatic tape laying machine (ATL).
  • ATL automatic tape laying machine
  • said lower skin being attached to the substructure by using rivets.
  • radius fillers or deltoid fillers are placed in angles shaped by intermediate structure extending away from the inner surface of the skin. In such way the bending moment can be absorbed in a better way, especially within the area of the transition region of the winglet.
  • the composite material used to form the substructure and skin may be of
  • the material used can be pre-impregnated woven fabric.
  • the material used can be dry woven fabric, in a second step injected or impregnated with resin.
  • the material used can be dry woven fabric interleaved with resin film.
  • the upper composite skin comprises reinforcing fibers or/and nano-sized inclusions, which are oriented transverse to the inner surface.
  • the transverse oriented reinforcement structure comprises CNTs (carbon nano tubes), which are grown in radial direction directly on individual large carbon fibers.
  • the transverse oriented fibers may be three dimensional carbon fiber fabrics (tailor made three dimensional fabrics and arrangement of stitched fabric assemblies to be adapted to the actual design).
  • Laminate materials may be based on pre-preg tape such as unidirectional pre-impregnated fiber plies, fibers being of woven carbon fiber pre-preg fabrics or glass, Kevlar, spectra pre-preg tapes and fabrics etc.
  • the transition region comprises transverse oriented elongated reinforcing fiber-like elements, such as reinforcing fibers and/or carbon nano tubes.
  • the skins of a wing root of the wing section also comprise transverse oriented elongated reinforcement fiber-like elements (such as reinforcing fibers and/or carbon nano tubes) for taking up high bending loads.
  • transverse oriented elongated reinforcement fiber-like elements such as reinforcing fibers and/or carbon nano tubes
  • the upper composite skin comprises transverse reinforcing fibers.
  • the reinforced composite skin comprises at least two plies.
  • Each skin ply may comprise large fibers, such as carbon fibers, graphite fibers and/or carbon nano tubes oriented in different directions.
  • a ply with span wise oriented carbon fibers could be laid onto and adjacent a ply with chord wise oriented carbon fibers and upon this one a further ply having 45 degrees oriented fibers relative the span wise direction.
  • Each ply can also comprise large fibers and/or carbon nano tubes (generic term for such large fibers and CNTs: elongated reinforcement fiber-like elements) oriented transverse relative the surface of the laminate stack. In such way the strength transverse the skin surface is achieved within the area of the transition region and a low weight structure can be achieved.
  • the fibers used for the transverse direction can be of the type used for span wise oriented fibers, which is cost-effective.
  • the transverse oriented elongated reinforcement fiber-like elements are carbon fibers.
  • the transverse oriented elongated reinforcement fiber-like elements are CNTs.
  • nano fibers, nano wires or other nano filament structures can be used.
  • the application of transverse oriented nano filaments relative the skin surface can be achieved in different ways. For example, growth of nano tubes onto large fibers, which large fibers extends in the plane of the skin. In such case, some of the nano filaments are oriented transverse.
  • Other examples may include a skin having all nano filaments oriented transverse the skin surface.
  • the composite skin comprises at least two plies and aligned transverse oriented CNTs being positioned between the plies for strengthening a bond between the plies in a transverse direction within the transition region.
  • the third fiber material of the three-dimensional-engineered fiber materials can include be aligned transverse oriented carbon nano tubes or nano wires in- between the plies.
  • An entire winglet may be produced with strengthening nano filament structures between and/or inside the plies, which structures or part of structures are oriented transverse the plane of the skin.
  • the substructure comprises transverse oriented reinforcing fibers being transverse oriented relative the inner surface.
  • the ribs and spar caps and beams and spars can be manufactures with high strength in a cost-effective way, especially within the area of the transition region.
  • the inner surface is fixed to the substructure via an adhesive comprising a nano filament structure, preferably within the curved transition region.
  • the substructure is a honeycomb material and the skins are adhered to the honeycomb outer surface.
  • a winglet profile formed to be fixed between a winglet tip section and a wing section, the winglet transition region being curved and having an upper and lower composite skin, wherein at least the lower reinforced composite skin comprises reinforcing fibers, which are oriented transverse to the inner surface.
  • a winglet transition profile for coupling a winglet tip to a wing tip is achieved.
  • the winglet transition profile is preferably curved after a line being transverse to a direction corresponding with the flight direction (during use of the article), which line follows the elongation of the winglet.
  • Carbon-fiber-reinforced polymer materials will allow the design and fabrication of structurally integrated curved structures such as winglets and similar curved structures.
  • the application of such curved structures, separately or in combination, will allow design solutions such as winglets, antenna fairings, curved landing gear doors, etc.
  • the method provides a curved structure (article) that involves high strength (having no heavy or turbulence generating disturbing details) within the curved transition region for counteracting the bending moment of the structure.
  • the design regards structures which are subjected to a bending moment, and which structures are curved in a transition region.
  • a curved antenna fairing having an interial structure bonded to a curved cover housing is also affected by bending loads and also comprises a corresponding transition region.
  • the bonding between the skin inner surface and the ribs are preferably made with an adhesive comprising transverse oriented fibers.
  • the composite skin comprises at least two plies with aligned transverse oriented carbon nano tubes being positioned between the plies for strengthening the joint between the plies in a transverse direction relative the ply plane and within the joint region.
  • the elongated reinforcement fiber-like elements exhibit through-thickness reinforcement with extension partly or entirely through one, more than one or all plies of the structural composite parts within the joint region.
  • the three-dimensional-engineered fiber material can include aligned transverse oriented carbon nano tubes or nano wires in-between the plies for further improvement of the peel strength.
  • the nano-sized elongated reinforcement fiber-like elements (CNT, nano fibre, nano multi wall filament, nano double wall filament, nano wire etc.) has a length of 0, 1 mm up to 3,0 mm for achieving improved strength between rib foot and skin. This is suitable for a common pre-preg ply having a thickness of 0, 125 mm used in the production of aircrafts. If leaning (relative laminate plane) nano-sized elongated reinforcement fiber-like elements are used, the length preferably can be longer.
  • the definition of nano is an element having at least one dimension not more than 200 nm. 1 nm (nanometre) is defined as 10 "9 metre (0,000 000 001 meter).
  • the diameter of a multiwall nano tube is 15-35 nm, suitably 18-22 nm.
  • the diameter of a single wall nano tube is 1 ,2-1 ,7 nm, preferably 1 ,35-1 ,45 nm. In such way the strength within the joint region of the structure being achieved in a cost-effective way.
  • the elongated reinforcement fiber-like elements exhibit through- thickness reinforcement with extension through the at least on ply with a
  • the through-thickness reinforcement may have an extension up to 1 ,5 mm into the skin laminate and into the flange of the rib foot respectively.
  • the curing tool is a hot drape tool.
  • a cost-effective method is achieved.
  • This is achieved by that a wing let manufacturer achieves dimensional control inside the hollow structure at the same time as faster curing cycles are used.
  • the use of laid-up pre-preg forming the skins gives the possibility to prepare the pre-preg tape, not only with in- plane arranged elongated reinforcement fiber-like elements but also with transverse arranged elongated reinforcement fiber-like elements.
  • the skins are preferably used for the curved transition region of the structure for absorbing the bending loads of the structure during flight.
  • the reinforced composite skin of the curved transition region is single curved or double curved.
  • the cure tool is an injection tool (RTM-resin transfer moulding).
  • the cure tool is an autoclave apparatus.
  • the cure tool is an out-of autoclave apparatus.
  • the laminate materials may be achieved by resin transfer moulding (RTM) in an automated operation that combines compression, moulding, and transfer moulding processes. In such way has been achieved a good surface finish and a dimensional stability in a cost-efficient way.
  • RTM resin transfer moulding
  • the mould is loaded with layers of dry fibers and the resin being injected or drawn into the mould. Some of the elongated reinforcement fiber-like elements are oriented transverse to the laminate surface.
  • the resin is heated and pressure is applied. After curing the curved article, such as the present winglet or winglet transition profile, is removed, trimmed, ID-marked and stored.
  • the method comprises the further step of applying aligned transverse oriented CNTs in position between at least two plies for strengthening the bond between the plies in transverse direction, preferably within the curved transition region.
  • An entire winglet may be produced with transverse oriented strengthening nano filament structures between and/or inside the plies, which nano structures or part of nano structures are oriented transverse the plane of the reinforced composite skin.
  • the method comprises the further step of fixing the inner surface of the single curved/double curved composite skin to the substructure via an adhesive comprising a nano filament structure, preferably within the transition region.
  • Fig. 1 illustrates a straight wing
  • Fig. 2 illustrates a wing comprising a winglet
  • Fig. 3 illustrates, in a perspective view, a wing comprising a winglet
  • Figs. 4a-4d illustrate examples of winglets
  • Figs. 5a-5c are illustrations of a retrofit (or detachable) winglet
  • Figs. 6a-6c are illustrations of a blended winglet of the type shown in Fig. 4c;
  • Figs. 7a-7d are illustrations of a blended winglet of the type shown in Fig. 4c according to an embodiment of the present invention.
  • Figs. 8a-8f illustrate a winglet comprising a transition region and a distal wingtip end
  • Fig. 8g illustrates a substructure bonding to a skin inner surface
  • Fig. 8h illustrates a three-dimensional-engineered carbon-fiber-reinforced materials
  • Figs. 9a-9e illustrate a method for manufacture of a curved airfoil structure
  • Figs. 10a and 10c illustrate a transition region of another curved article of an aircraft
  • Fig. 10 b illustrates prior art transition region
  • Figs. 1 1 a and 1 1 b illustrate different types of moulding tools
  • Fig. 12 illustrates an autoclave apparatus.
  • Fig. 1 schematically illustrates an ordinary straight wing 1 of an aircraft 2 seen from front in a direction corresponding with the direction of airflow or direction of flight.
  • a vortex 5 is formed due to the difference in air pressure between upper 7 and lower 9 surfaces (under pressure U and over pressure 0) of the wing 1 .
  • Air is caused to escape around the wingtip 3 which will reduce the lift and increase the drag of the aircraft 2.
  • Fig. 2 schematically illustrates a wing 1 1 comprising a winglet 13.
  • the outboard sections of the wing 1 1 will produce more lift.
  • an inward pointing load is generated by that the winglet 13 relocates the wingtip vortex 5 and produces a bending moment M to the wing 1 1 and winglet 13, especially in an area called the curved transition region 15 defined between the wing 1 1 and the winglet 13.
  • the bending moment M' adjacent the wing's 1 1 root 17 increases significantly when the winglets 13 are used.
  • the winglet 13 thus produces an inward load as it diverts the tip vortex 5 outward.
  • the wingtip will generate more lift which also increases the bending moments M, M'.
  • Fig. 3 schematically illustrates in a perspective view a wing 1 1 comprising a winglet 13.
  • the Fig. 3 illustrates three axes X, Y, Z.
  • the span wise direction essentially extends along the Y-axis.
  • the chordwise direction of the wing 1 1 essentially corresponds with the X-axis.
  • the third axis is the Z-axis, which is orthogonal to the X- and Y-axes.
  • the winglet 13 and transition region 15 exhibits a curvature, which curves in a direction towards the Z-axis.
  • FIGs. 4a-4d different types of winglets 13 are schematically illustrated in
  • Fig. 4a illustrates a blended winglet 13 with a high degree of sweep relative the rest of the wing 1 1 .
  • the dihedral angle is near constant and the winglet 13 is almost planar in a direction extending with a sharp angle relative to the Z-direction and a transition region 15 between the wing 1 1 and the winglet 13 root 17 being curved.
  • Fig. 4b illustrates a retrofit winglet 13 being mounted onto a wingtip 21 .
  • winglet 13 is thus attached to the wingtip 21 in a way resulting in relatively sharp corners 23 of the transition region 15 having a curvature of small radii.
  • Fig. 4c illustrates a blended winglet 13 with a low degree of sweep relative the rest of the wing 1 1 .
  • the blended winglet 13 exhibits a smooth curve which reduces shock interference between wing 1 1 and winglet 13.
  • the transition region 15 is formed with a nearly constant radius of curvature of sweep.
  • Fig. 4d illustrates a wingtip fence 13', which also functions to relocate the wingtip vortex of the wing 1 1 further outboard.
  • This kind of winglet 13' also comprises a transition region 15. However, this region exhibits a small radius of curvature of structure.
  • an inward pointing load is generated by the wingtip fence 13' (for relocating the wing tip vortex) which produces a bending moment to the curved transition region 15.
  • Fig. 5a schematically illustrates a side view of a cut-away of the retrofit or detachable winglet 13 shown in Fig. 4b.
  • a winglet root 19 of the winglet 13 is attached to the wing's 1 1 wingtip 21 .
  • Bolts 25 mechanically connect the winglet 13 to the wingtip 21 .
  • An upper 27 and lower 29 skin are attached to a substructure 31 of the winglet 13 and wing 1 1 and also of the transition region 15.
  • a structural rib 33 is affixed to the substructure 31 and designed with a curvature.
  • the upper 27 and lower 29 skins of graphite epoxy are provided with carbon nano tubes (not shown).
  • the carbon nano tubes are oriented in a direction orthogonally to the upper 27 and lower 29 skin surface.
  • the orthogonally oriented carbon nano tubes of upper skin 27 take up forces acting on the upper skin 27 (inboard skin 27'), which forces will compress the skin 27 in a direction parallel with the plane of the upper skin 27.
  • the orthogonally oriented carbon nano tubes of lower skin 29 take up forces acting on the lower skin 29 (outboard skin 29') with tension in a direction parallel with the plane of the lower skin 29.
  • the winglet 13 is attached to wing tip ribs 34 by means of the bolts 25.
  • a spar cap 35 and a root rib 37 of graphite epoxy are provided for acting with bending stiffness and strength to the transition region 15 at a minimum weight.
  • the inboard 27' and outboard 29' skins are made of laid up CFRP or another structural composite material.
  • the bending stiffness being provided by the orthogonally oriented carbon nano tubes and by the fiber reinforced plastic substructure 31 . Shear forces within the skins 27, 29 will be counteracted by the application of the transverse (relative the plane or extension of skins) oriented carbon nano tubes.
  • Fig. 5b schematically illustrates from above the section A- A in Fig. 5a of the transition region 15.
  • the structural wing tip ribs 34 are formed by middle and aft wing rib 39 and the ribs of the winglet 13 are attached via the bolts (not shown) to said wing ribs 39.
  • Fig. 5c is a further view illustrating the winglet 13 in Fig. 5a from the side.
  • Fig. 6a schematically illustrates a blended winglet 12 of the type shown in Fig. 4c and is made according to prior art.
  • the blended winglet 12 exhibits a low degree of sweep and a smooth curve which reduces shock interference in the transition region 15.
  • the upper and lower skins of the transition region 15 is made of epoxy or other resin pre-preg plies being reinforced by carbon or other fibers (e.g. cyanate ester) extending in a direction parallel with the skin extension.
  • Such blended winglet 12 according to prior art must be re-inforced within the curved transition region 15 because of the increased bending moment of the wingtip 3.
  • FIG. 6b schematically illustrates in a closer view from above a section of the prior art skin regarding the fiber orientation.
  • each ply P comprises fibers f having a specific orientation in a common plane so that when all plies P are laid up onto each other, the laminate skin exhibits fiber directions of 0 degrees, 90 degrees, +/-45 degrees parallel with the skin plane.
  • Fig. 6c schematically illustrates a cross section of a skin laminate according to prior art within the transition region 15.
  • each ply P comprises fibers f having an orientation along the plane of the skin within the transition region 15.
  • Fig. 7a schematically illustrates a blended winglet 13 of the type shown in Fig. 4c according to an embodiment of the present invention.
  • the wing skins (upper 27 and lower 29, only upper 27 being shown) within the transition region 15 between the wing 1 1 and the winglet 13 also comprises reinforcement (carbon) fibers 41 being oriented transverse to the skin plane extension EX.
  • a section of the skin is shown in Fig. 7b from above (within the curved transition region 15) with a more detailed fiber orientation.
  • the laminate skin 27 exhibits fiber directions in 0 degrees, 90 degrees, +/-45 degrees as the skin shown in Fig. 6, but also carbon fibers 41 exhibiting a transverse orientation relative the skin 27, 29 plane.
  • Fig. 7a schematically illustrates a blended winglet 13 of the type shown in Fig. 4c according to an embodiment of the present invention.
  • the wing skins (upper 27 and lower 29, only upper 27 being shown) within the transition region 15 between the wing 1 1 and the winglet 13 also
  • each ply P comprises fibers f having an orientation parallel with the plane extension EX of the skin 27 within the transition region 15 and also comprises transverse fibers 41 having an orientation transverse to the skin 27 plane extension EX.
  • a winglet 13 achieved which has high strength and low weight. Saving weight means that also fuel is saved. No further material has to be used for strengthening the winglet 13 for mounting the latter to the wing 1 1 and therefore no rivet heads will make any turbulence, instead is achieved a smooth aerodynamic surface of the transition region 15, which also saves fuel during flight.
  • the upper skin 27 (inboard skin) is affected by forces pressing (compressing in a direction corresponding with the plane extension EX) the skin 27 whereby the skin 27 has a tendency to delaminate and the forces will make a tension F1 of the laminate in a direction orthogonally to the skin 27 surface and in a direction from the latter.
  • the lower skin 29 (outboard skin) is affected by forces making a traction action upon the skin 29 whereby the skin 29 (and the plies of the skin 29) has a tendency to become thinner by compressing forces F2.
  • the substructure 31 is positioned between the skins 27, 29. No additional nor superfluous strengthening structures such as ribs, spar caps, stringers etc. have to be mounted within the transition region 15 for taking up the bending moment M.
  • the substructure 31 can be made with less reinforcing material due to the new property of the skins 27, 29.
  • Each ply thus comprises portions of large fibers 41 oriented transverse relative the surface of the skin 27, 29 and the laminate stack plane extension EX. In such way completary strength in a direction transverse the skin 27, 29 surface (or plane extension EX) being achieved within the transition region 15 and thereby a low weight structure can be achieved.
  • Figs. 8a-8f schematically illustrate a winglet 13 comprising a transition region 15 and a distal wingtip 21 end.
  • the transition region 15 is defined between a winglet tip section 42 of the winglet 13 and a wingtip 21 of the wing 1 1 .
  • the wing 1 1 extends along an Y-axis.
  • the wing's 1 1 wing chord extends along an X-axis. These axes are perpendicular to a Z-axis.
  • the transition region 15 is curved, wherein the winglet tip section 42 declines towards the Z-axis.
  • the winglet's 13 transition region 15 comprises an upper 27 and lower 29 composite skin.
  • the respective skin 27, 29 exhibits an inner surface 45 being fixed to ribs 47 forming a substructure 31 of the winglet 13.
  • Each skin 27, 29 comprises a reinforcing fiber structure in the form of carbon fibers.
  • the wingtip 21 end is adapted for attachment of the winglet 13, wherein the substructure 31 of the winglet 13 being pushed into the wing 1 1 structure.
  • a cross section A-A is shown in Fig. 8b (the ribs 47 have been co-cured with upper 27 and lower 29 skins in one curing cycle process).
  • Upper 49 and lower 50 flanges of the ribs 47 are bonded with the inner surfaces 45 of the respective upper 27 and lower 29 skins.
  • Fig. 8b is shown an area defined by a dashed and dotted circle line, which area is illustrated in Figs. 8c-8f by examples of the
  • FIG. 8c illustrates lower flange 50 adhered to the inner surface 45 of the winglet 13 skin 29 of a transition region 15.
  • An adhesive 51 bonds the flange 50 with the inner surface 45.
  • the adhesive 51 comprises an epoxy and carbon nano tubes CNT's 43' having an orientation perpendicular to the plane of the inner surface 45.
  • the reinforcing fiber structure (not shown) of the lower composite skin 29 thus comprises the adhesive 51 including reinforcing fibers 43', which are oriented transverse to the inner surface 45.
  • the adhesive 51 is defined as a portion of the skin 29.
  • FIG. 8d illustrates a further embodiment.
  • Plies P of pre-pregs (beforehand resin impregnated fiber sheets) have been stacked onto each other.
  • the plies P are laid by means of an ATL-apparatus (not shown).
  • the transverse oriented reinforcing fibers are in this embodiment elongated nano wires 43", which are arranged in such way that a major part of them joins two adjacent plies P, wherein the interface bond between the plies P is strengthened in transverse direction by means of the transverse nano wires 43".
  • Fig. 8e A further embodiment is shown in Fig. 8e.
  • transverse nano fibers 43"' are disposed within each ply P in a transverse direction relative the ply P extension.
  • Fig. 8f wherein some of carbon nano tubes 43"" (of a growth of aligned carbon nano tubes NF onto large fibers f of the plies P) are oriented transverse to the skin 29 extension.
  • the large fibers f extend along the plane of the skin 29.
  • Fig. 8g schematically illustrates a flange 50 of a rib bonded to an inner surface 45 of a skin 29 within a curved section of an airframe subjected to bending moments.
  • the flange 50 of the substructure comprises transverse oriented nano tubes.
  • Fig. 8h illustrates a further embodiment.
  • a three-dimensional-engineered carbon- fiber-reinforced material 3D is applied to the plies P for bonding them together.
  • Figs. 9a-9e schematically illustrate a method for manufacture of a winglet.
  • the semi-cured skin 55 is applied in the tool's 58 bottom forming part and well defined substructure semi-cured ribs 59 are placed onto and fixed to the skin 55 inner surface in contact with interior forming fly away tool parts (not shown).
  • An upper semi-cured skin 55' is applied onto the substructure 31 .
  • the design in this case regards dual-skin structures (upper and lower skin) having a sub-structure 31 (supporting structure in the form of spars, ribs and/or beams) there between.
  • Ribs 59 are chordwise structures (extending in the direction of flight) connecting together the upper 55' and lower 55 skin (also called inboard and outboard skin within the area of the finished winglet 13).
  • the function of the ribs is to maintain the aerodynamic profile of the wing and winglet. They also transfer air pressure (over-/under pressure) from the skins 27, 29 to the spar caps 35 and they diffuse locally concentrated load inputs and they function to redistribute wing bend loads and winglet root bend moment loads
  • Fig. 9c is shown an upper part of the moulding tool 58 for forming the winglet 13.
  • the winglet 13 thus comprises the curved transition region 15 having an upper 27 and lower 29 composite skin, each comprising an inner surface fixed to the substructure 31 , wherein each composite skin 27, 29 comprises a reinforcing fiber structure at least partly having a fiber orientation being transverse to the inner surface 45.
  • Curing of the winglet 13 is made by a co-curing process (not shown) and the winglet 13 is removed from the moulding tool 58 after curing, as is shown in Fig. 9d.
  • Fig. 9e is shown the winglet 13' mounted to a wing 1 1 .
  • the winglet 13' comprises a curved transition region 15 (comprising the upper 27 and lower 29 composite skin, each exhibiting a reinforcing fiber structure which at least partly having a fiber orientation being transverse to the inner surface 45 shown in Fig. 9c).
  • Fig. 10a illustrates a transition region 15 of another structurally integrated curved structure of air stream dividing flap 13" of an aircraft, which curved structure takes up a bending moment during the use of the structure.
  • Tension forces strive for making the lower skin 29 thinner and break up the bond between the substructure 31 and the skin 29 inner surface.
  • Compression forces C strive for making the skin thicker and delaminating the skin 29.
  • the curved flap 13" article being affected by a bending moment M, during its use and motion through the air stream.
  • a curved flap having a weak substructure according to prior art will over time delaminate as shown in Fig. 10b.
  • Fig 10c schematically illustrates transverse fibers 43 according to a further example of the actual flap 13" in Fig. 10a according to a further embodiment of the present invention.
  • Some structural fibers of the transition region 15, such as transversal fibers 43, are arranged within the lower skin 29 for counteracting the tension of the skin 29 caused by moment M.
  • Fig. 1 1 a schematically illustrates a moulding tool which is a hot drape tool 58'.
  • Fig. 1 1 b schematically illustrates a moulding tool which is an infusion tool 58".
  • the laminate materials are in this example produced by resin transfer moulding (RTM) in an automated operation that combines compression, moulding, and transfer moulding processes.
  • the moulding tool 58" is loaded with layers (not shown) of fibers and the resin being injected into the tool. Some of the fibers are oriented transverse to the laminate surface. The resin is heated and pressure is applied. After curing, the structural integrated curved structure (not shown) is removed, trimmed, painted, ID-marked and stored.
  • Fig. 12 illustrates an autoclave apparatus AC.
  • the lay-up LU comprising the elongated reinforcement fiber-like elements (oriented transverse relative the surface of the laminate stack) is placed onto male tools MT.
  • the lay-up is enclosed by a vacuum bag VA and being evacuated. Subsequently the lay-up and vacuum bag moved into the autoclave apparatus for pressurizing the lay-up under application of heat for curing the lay-up forming the winglet.
  • the method provides a curved article that involves high strength (having no heavy or turbulence generating disturbing details) within the transition region for counteracting the bending moment of the article.
  • the use of three-dimensional-engineered e.g. CFRP (Carbon-fiber-reinforced polymer) materials will allow the design and fabrication of structurally integrated curved structures.
  • CFRP Carbon-fiber-reinforced polymer
  • the application of such curved structures, separately or in combination, will allow design solutions, such as winglets, antenna fairings, curved landing gear doors, etc.
  • the design regards structures which are subjected to a bending moment, and which structures are curved in a transition region.
  • a curved antenna fairing having a structural interior bonded with curved cover housing is also affected by bending loads and also comprises a corresponding transition region.
  • the bonding between the skin inner surface and the ribs are made of adhesive comprising transverse oriented fibers, carbon nano tubes or similar reinforcement.
  • the present invention is of course not
  • suitably composite materials include carbon fibers, aramid fibers, glass fibers, combinations of carbon and glass fibers or combinations of carbon, aramid and glass fibers.
  • the skins and the substructure may be provided by laminating multiple sheets or layers having the fibers of respective sheet oriented in different directions, however having at least within the area of the transition region of the winglet, fibers, nano tubes or similar reinforcements oriented transverse the sheets major extension.
  • the invention is not limited to aircraft. Also other aerial vehicles can be actual for implementation of the invention. Instead of winglet, the word integrated curved structure may be used. Such structure may be used also for applications not related to aerial vehicles, but wind mills, high speed trains etc. The design could also regard a curved structure having outboard and inboard skins arranged against a distance holding structural honeycomb.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Aviation & Aerospace Engineering (AREA)
  • Moulding By Coating Moulds (AREA)

Abstract

La présente invention concerne une structure incurvée (13, 13', 13'') structuralement intégrée comprenant une région de transition incurvée (15) délimité entre une section pointe (42) et une section base (11, 21), des revêtements composites supérieur et inférieur (27, 29) comprenant une surface intérieure (45) fixée à une sous-structure (31) de ladite région de transition (15), la sous-structure (31) et les revêtements (27, 29) étant, lors de l'utilisation de la structure (13, 13', 13''), soumis à un moment de pliage (M), chaque revêtement (27, 29) de ladite région de transition (15) comprenant des éléments allongés du type à fibres de renforcement. Le revêtement composite inférieur (29) comprend des fibres de renforcement et/ou des nanotubes (41, 43), qui sont orientés de manière transversale à la surface intérieure (45). L'invention se rapporte également à un procédé de production de la structure incurvée structuralement intégrée (13, 13', 13'').
PCT/SE2012/051126 2012-10-22 2012-10-22 Structure intégrée incurvée et amélioration de la résistance d'ailette WO2014065718A1 (fr)

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EP12887291.8A EP2909009A4 (fr) 2012-10-22 2012-10-22 Structure intégrée incurvée et amélioration de la résistance d'ailette
PCT/SE2012/051126 WO2014065718A1 (fr) 2012-10-22 2012-10-22 Structure intégrée incurvée et amélioration de la résistance d'ailette

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GB2522245A (en) * 2014-01-20 2015-07-22 Airbus Operations Ltd A curved winglet
WO2016092293A1 (fr) * 2014-12-09 2016-06-16 Short Brothers Plc Composants renforcés par des fibres comprenant des nanostructures
WO2017046250A3 (fr) * 2015-09-17 2017-06-15 Rolls-Royce Deutschland Ltd & Co Kg Élément structural d'une partie d'avion et procédé de fabrication d'un élément structural
US20170341737A1 (en) * 2016-05-24 2017-11-30 Airbus Operations Limited Winglet
CN107521124A (zh) * 2017-07-31 2017-12-29 江苏恒神股份有限公司 碳纤维双面板加筋结构件及其制造方法
EP2881321B1 (fr) 2013-12-05 2018-07-11 The Boeing Company Split winglet monobloc en composite
EP3363734A1 (fr) * 2017-02-17 2018-08-22 Airbus Operations Limited Agencement de nervure dans un dispositif d'extrémité d'aile
EP3473539A1 (fr) * 2017-10-19 2019-04-24 Airbus Operations Limited Ensemble d'aéronef comprenant un dispositif de bout d'aile
CN109684679A (zh) * 2018-12-04 2019-04-26 中国航空工业集团公司西安飞机设计研究所 一种承受反对称集中载荷的圆拱形加强框参数设计方法
WO2019245827A1 (fr) * 2018-06-21 2019-12-26 Sierra Nevada Corporation Dispositifs et procédés pour fixer un noyau composite à une structure environnante

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EP2881321B1 (fr) 2013-12-05 2018-07-11 The Boeing Company Split winglet monobloc en composite
EP2881321B2 (fr) † 2013-12-05 2022-07-13 The Boeing Company Split winglet monobloc en composite
US10336440B2 (en) 2014-01-20 2019-07-02 Airbus Operations Limited Curved winglet
GB2522245A (en) * 2014-01-20 2015-07-22 Airbus Operations Ltd A curved winglet
WO2016092293A1 (fr) * 2014-12-09 2016-06-16 Short Brothers Plc Composants renforcés par des fibres comprenant des nanostructures
EP4223501A1 (fr) * 2014-12-09 2023-08-09 Short Brothers Plc Composants renforcés par des fibres comprenant des nanostructures
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US20170341737A1 (en) * 2016-05-24 2017-11-30 Airbus Operations Limited Winglet
US10597145B2 (en) * 2016-05-24 2020-03-24 Airbus Operations Limited Winglet
US10864983B2 (en) 2017-02-17 2020-12-15 Airbus Operations Limited Rib arrangement in a wing tip device
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GB2559771A (en) * 2017-02-17 2018-08-22 Airbus Operations Ltd A rib arrangement in a wing tip device
EP3363734A1 (fr) * 2017-02-17 2018-08-22 Airbus Operations Limited Agencement de nervure dans un dispositif d'extrémité d'aile
CN107521124A (zh) * 2017-07-31 2017-12-29 江苏恒神股份有限公司 碳纤维双面板加筋结构件及其制造方法
EP3473539A1 (fr) * 2017-10-19 2019-04-24 Airbus Operations Limited Ensemble d'aéronef comprenant un dispositif de bout d'aile
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WO2019245827A1 (fr) * 2018-06-21 2019-12-26 Sierra Nevada Corporation Dispositifs et procédés pour fixer un noyau composite à une structure environnante
GB2587740A (en) * 2018-06-21 2021-04-07 Sierra Nevada Corp Devices and methods to attach composite core to a surrounding structure
US11167836B2 (en) 2018-06-21 2021-11-09 Sierra Nevada Corporation Devices and methods to attach composite core to a surrounding structure
GB2587740B (en) * 2018-06-21 2022-11-02 Sierra Nevada Corp Devices and methods to attach composite core to a surrounding structure
CN109684679A (zh) * 2018-12-04 2019-04-26 中国航空工业集团公司西安飞机设计研究所 一种承受反对称集中载荷的圆拱形加强框参数设计方法

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