Abstract: A method of forming a wind turbine blade shear web flange section (36) by resin transfer moulding comprises providing a mould assembly (84) comprising a mould surface (86) defining a mould cavity and arranging a plurality of elongate flange elements (46) with the mould surface in an array (80) such that the flange elements are positioned one on top of another with first and second longitudinal ends (56,60) of each flange element longitudinally offset from respective first and second longitudinal ends of a neighbouring flange element so as to form a tapered portion (58,62) at each of a first and second longitudinal end of the flange section (36). A The method further comprises injecting resin to the mould cavity and curing the array of flange elements in a resin matrix to form a cured flange section having a laminate construction.

Abstract: A shear web flange (36) for a shear web (32) of a wind turbine blade (18) is described. The flange (36) extends longitudinally and comprises a bonding surface (50) for bonding to an inner surface of a wind turbine blade (18). One or more protruding features (52a, 52b) protrude from the bonding surface (50). A method of making such a shear web flange (36) is also described as are a shear web (32) for a wind turbine blade (18), a wind turbine blade (18) and a method of making a wind turbine blade (18).

Abstract: An assembly apparatus for forming an interfay joint during manufacture of an aircraft (10). The assembly apparatus includes an assembly jig (40) to hold a first joint component (26), and an applicator (43) configured to apply an uncured layer of shim to the first joint component. The assembly jig locates, subsequent to the uncured layer of shim being applied, a second joint component (23) in an assembled joint position spaced from the first joint component. As such the uncured layer of shim is compressed between the first and second joint components. A method of forming an interfay joint during manufacture of an aircraft, an interfay joint for an aircraft, an aircraft aerodynamic surface, an aircraft, and a shim layer applicator.

Abstract: Flexural digital materials are discrete parts that can be assembled into a lattice structure to produce an actuatable structure capable of coordinated reversible spatially-distributed deformation. The structure comprises a set of discrete flexural digital material units assembled according to a lattice geometry, with a majority of the discrete units being connected, or adapted to be connected, to at least two other units according to the geometry. In response to certain types of loading of the structure, a coordinated reversible spatially-distributed deformation of at least part of the structure occurs. The deformation of the structure is due to the shape or material composition of the discrete units, the configuration of connections between the units, and/or the configuration of the lattice geometry. Exemplary types of such actuatable structures include airplane wing sections and robotic leg structures.

Abstract: The invention relates to a control surface element for an airplane, in particular a spoiler, comprising a composite fiber element that has a surface around which air flows, a mounting device for movably mounting the composite fiber element on a structural component, and a reinforcing structure for reinforcing the composite fiber element. The reinforcing structure comprises at least one reinforcing element which is integrally formed with the composite fiber element. The reinforcing structure comprises a primary reinforcing element which is designed to receive main loads and which is connected to at least one secondary reinforcing element that is designed to receive secondary loads. The composite fiber element comprises a recess for integrally forming the primary reinforcing element.

Abstract: An aerofoil shaped body includes a plurality of longitudinal spars, an upper aerofoil cover, and a lower aerofoil cover. The spars and the covers are made of composite laminate material. One of the spars is integrally formed with one of the covers to form a spar-cover such that the composite laminate material of the spar extends continuously into the cover through a fold region created between the spar and the cover. The fold region has a fold axis extending substantially in the longitudinal direction, and the fold axis projected onto two orthogonal planes has curvature in both those planes.

Abstract: An aircraft wing torsion box having a front associated with a leading portion of the wing torsion box and a rear associated with a trailing portion of the wing torsion box. The wing torsion box includes a support member having a front spar and a rear spar and a connecting portion between the front and rear spars, the connecting portion includes at least one interposing spar, at least one portion of upper wing skin; and at least one portion of lower wing skin, and at least one portion of the upper wing skin and at least one portion of the lower wing skin being supported by the support member.

Abstract: A flow body for an aircraft with a leading edge and a trailing edge includes a first spar, a second spar, and an external skin that spans from the leading edge to the trailing edge and on both sides rests on the spars. At least one of the first spar and the second spar includes a web and two spaced-apart flanges that enclose the web, on which flanges the skin that spans the respective spar is arranged. At least one of the first spar and the second spar includes at least one load introduction fin that forms an integral component with the web and extends outwards by way of one of the flanges and the skin that rests on the spars.

Abstract: An improved monument structure combining an integrated construction system with carbon fiber reinforced composites to form an exoskeleton chassis that significantly reduces the build times, manufacturing skill level requirements, post processing activities, and overall weight of a given aircraft monument.

Abstract: Flexural digital materials are discrete parts that can be assembled into a lattice structure to produce an actuatable structure capable of coordinated reversible spatially-distributed deformation. The structure comprises a set of discrete flexural digital material units assembled according to a lattice geometry, with a majority of the discrete units being connected, or adapted to be connected, to at least two other units according to the geometry. In response to certain types of loading of the structure, a coordinated reversible spatially-distributed deformation of at least part of the structure occurs. The deformation of the structure is due to the shape or material composition of the discrete units, the configuration of connections between the units, and/or the configuration of the lattice geometry. Exemplary types of such actuatable structures include airplane wing sections and robotic leg structures.

Abstract: A modular fiber reinforced plastic flange for a structural composite beam which comprises a body formed of a plurality of elongate elements arranged in an array, wherein the dimensions of the body are substantially determined by the number and arrangement of the elongate elements in the array, and a skin member at least partially surrounding the array. Also, a structural composite beam comprising the modular fiber reinforced plastic flange and a shear web connected to the skin member of the modular flange. A method of making the modular flange and beams, and a kit of parts for making the modular flange are also disclosed.

Abstract: The present invention relates to a stringer, particularly to a stiffening and structural longitudinal element for skin of aircraft airfoil surfaces, characterized in that it incorporates two separate and independent reinforcement areas, one in the foot and the other at the end of the web (head) of the stringer, where the reinforcement areas are obtained by a widening of the section of the stringer, the widening being formed by a localized stack of reinforcing plies of composite material which are embedded within the stringer. The invention also relates to the method of manufacture and is particularly applicable to stringers having an L-shaped or T-shaped section.

Abstract: A wind turbine component incorporating radar-absorbing material having increased compatibility with lightning protection systems is described. The radar absorbing material includes a ground plane having an electrical conductivity and/or a dielectric constant that is higher in the presence of an electric field having a frequency of 1 GHz and above than in the presence of an electric field having a frequency of 10 MHz and below. Suitable materials for the ground plane include ferroelectric and ferrimagnetic materials and percolating material combinations, all of which have frequency-dependent properties that can be tuned to make the ground plane highly reflective at radar frequencies and benign at lightning discharge frequencies.

Abstract: A composite laminate patch for reworking an inconsistent area in a structure has inner and outer control regions possessing differing interlaminar fracture toughnesses for controlling the advance of a disbond in the patch. One or more separation zones in the patch between the control regions aids in diffusing the fracture energy of the disbond as the disbond advances from the inner region to the outer region.

Abstract: A composite frame includes a plurality of truss elements covered by a cap. The truss elements are flexibly coupled with each other and with the cap. The frame flexes to conform to a contoured surface to which it is attached. Once attached, the installed frame provides the required rigidity to the structure.

Abstract: Processes for fabricating an integrated fiber-reinforced cured resin-composite panel structure include forming a panel preform assembly by (i) positioning pre-cured fiber-reinforced resin-composite tubular stiffeners onto an uncured base skin, and (ii) applying uncured fiber-reinforced resin-composite overlapping layers onto the pre-cured stiffeners so that at least lateral edges of the overlapping layers are laminated to a corresponding region of the base sheet; and thereafter curing the fiber-reinforced resin-composite base skin and overlapping layers to thereby form an integrated composite panel structure.

Abstract: The invention provides a prepreg comprising matrix and fibers, having deposited thereon a plurality of regions raised at least 5 micrometers relative to the surface of the matrix, a method of preparing such a prepreg, a method of curing a laminate of a plurality of such preprags and the cured laminate produced by such a method.

Abstract: The invention relates to a composite structuring panel (1) for the trailing edge of an aircraft element, having: an upper surface (3); a lower surface (5); an edge (7) connecting said upper (3) and lower (5) surfaces; the upper surface (3) and the lower surface (5) being connected by transverse stiffeners (9) and the structuring panel being made of a unitary part forming the upper surface (3), the lower surface (5), the edge (7), and the transverse stiffeners (9). The invention also relates to a method for manufacturing such a panel (1), and to an aircraft element comprising such a panel (1).

Abstract: A structural assembly for an aircraft comprising a cover with outer and inner faces, an inner support element and urging means on the inner support element, wherein opposing edges of the cover are fixedly mounted relative to the inner support element, and the urging means acts on the inner face of the cover to urge the cover to distend outwardly and locate in a predetermined position. Another aspect of the invention relates to a method of forming a structural assembly for an aircraft comprising an cover with outer and inner faces, an inner support element and urging means on the inner support element, the method comprising the steps of fixedly mounting opposing edges of the cover relative to the inner support element and operating the urging means to act on the inner face of the cover so that the cover is urged to distend outwardly into a predetermined position.

Abstract: A composite structure has a first section, a second section, and a curved corner joining the first and second sections. The structure has a stack of fiber-reinforced plies including first and second external plies which run from the first section into the second section on an inside and an outside of the corner, respectively. A discontinuous first internal ply is sandwiched between the first and second external plies so that more of the first internal ply is located within the first section than within the second section. A second internal ply is sandwiched between the first and second external plies. The fibers of the first internal ply run at an angle ? to the fibers of the second internal ply. In some embodiments the angle ? is greater than 3° but less than 20°. In one embodiment the angle ? is between 35° and 42°.

Abstract: A composite structure has first and second sections, and a curved corner joining the first and second sections. The structure includes a stack of fiber-reinforced plies. First and second external plies run from the first section into the second section round an inside and an outside of the corner, respectively. First and second internal plies are sandwiched between the first and second external plies, and run from the first section into the second section round the corner. The first internal fly is dropped off inside the second section. The second internal ply is dropped off inside the first section. The structure has an increased thickness where the first and second internal plies overlap.

Abstract: The disclosed embodiments concern a curved structural part composed of a composite material with reinforced, continuous fibers whose cross section includes at least two wings, with said fibers extending from one wing to the other, with said structural part having a variation in the width of its section parallel to the local radius of curvature. The structural element that results from assembling the parts in the disclosed embodiments therefore has local widening of the section at the connections between the parts constituting a structural element, such as an aircraft fuselage frame, and widening at the connection with the floor profiles, if such a profile is used to make an aircraft fuselage structure. The disclosed embodiments also concern a process for manufacturing such a part, as well as a device for advantageously implementing such a process.

Abstract: A vent stringer 20 is formed by a pair of ribs 21 rising in the direction perpendicular to an inner surface 11a of a wing panel 11, and a cover 22 provided in the tip end portions of the ribs 21. With rivets 23 unexposed to an outer surface 11b of the wing panel 11, a spark is prevented from occurring in a fuel tank 30, which is provided in a main wing 10, through the rivet 23 at the time of a lightning strike. Formed by being machined integrally with the wing panel 11, the rib 21 is formed with high accuracy so as to match the curved shape of the wing panel 11. The cover 22 has only to be formed by curving a strap member so as to match the shapes of the wing panel 11 and the ribs 21.

Abstract: A laminate of metal layers and plastic bonding layers situated between the metal layers includes two external metal layers extending substantially continuously and at least one internal metal layer. At least one of the internal metal layers has at least one opening, and at the position of the opening the other metal layers and plastic bonding layers are bonded together to the form of a packet of lower thickness. The relatively thick parts of the laminate can be used for the transfer of forces.

Abstract: The present invention relates to an aircraft load frame (1) made of a composite material, characterized in that it comprises two side elements (2, 3) and a base element (7), the side elements (2, 3) being joined at the inner part of the frame (1) by means of the base element (7) and each of the side elements (2, 3) comprising a leg (4) joining the frame (1) to the aircraft fuselage skin, a web (5) and a lower flange (6) joining the web (5) and the base element (7).

Abstract: Techniques and apparatus for providing a fly away caul plate are disclosed. In an embodiment, a method for curing a composite structure includes placing a pre-cured caul plate proximate an uncured composite lay-up, the lay-up may or may not include one or more stiffeners extending substantially perpendicular to the lay-up surface, the caul plate including an aperture for receiving the at least one stiffener. A force may be exerted against the caul plate to engage the composite lay-up. Heat and/or pressure may be applied to the composite lay-up to cure the stiffener panel and co-bond the caul plate to the composite lay-up.

Abstract: The invention relates to a method for producing a structural composite trailing edge panel (1) for an aircraft element having: an upper surface (3), a lower surface (5), and a trailing edge (7) connecting said upper (3) and lower (5) surfaces, the upper surface (3) and the lower surface (5) being connected by transverse stiffeners (9), at least one longitudinal spar (10) being positioned in such a way that the directrix (?10) of each longitudinal spar (10) and the directrix (?9) of the transverse stiffeners (9) are not collinear and the structuring panel (1) being made up of a one-piece component forming the upper surface (3), the lower surface (5), the trailing edge (7), the transverse stiffeners (9) and the spar or spars (10).

Abstract: A composite panel having a first skin forming the outer wall of the panel, known as the lower face (1), and a second skin forming part of the inner wall of the panel. The second skin is formed hollow such as to produce an inner reinforcing frame (2) in the form of a half-box structure (3) which, together with the first skin, forms box parts. The aforementioned frame is equipped with a rim (4a, 4b) for fixing to the first skin, a face known as the upper face (5) and connecting side walls (6, 6a, 6b, 6c, 6d, 6e, 7) between the rim (4a, 4b) and the upper face (5) the first and second skins forming a monolithic self-stiffened panel. The half-box frame (2) has perforated sections (8) which are defined by hollow beam sections forming the half-box frame (2).

Abstract: A structural element includes the following elements: a carrier element, a reinforcing element, and a sheathing element. At least a portion of the reinforcing element is enveloped by the sheathing element and the reinforcing element is embedded in the carrier element. Materials of the elements are selected to inhibit crack initiation or propagation in the elements and/or from one element to another. An intermediate layer of a different material may be added between elements to further inhibit crack initiation and propagation and to inhibit corrosion, such as galvanic corrosion.

Abstract: A single piece co-cured composite wing is disclosed. The wing has a flying surface and structural members. In one embodiment the structural members may be a plurality of spars. The spars may have various shapes to increase the buckling strength. The spars may be wave shaped, such as a sinusoidal shape. The flying surface and the structural members are co-cured in order to form a single piece, integral wing structure. A process for manufacturing a single piece co-cured wing is also disclosed. The process may include laying out composite sheets for the flying surface of the wing. Then, the composite material of the spars is arranged around a plurality of pressurizable forms. Finally, the composite material is cured in a clamshell frame. A single piece co-cured composite structure is also disclosed that includes an outer skin, and inner skin, a frame, and a stringer.

Abstract: A wing panel structure for an aerospace vehicle or the like may include an outer layer of material having a predetermined thickness. A core structure may be placed on at least a portion of the outer layer of material. An inner layer of material may be placed at least on the core structure. The inner layer of material may have a selected thickness less than the predetermined thickness of the outer layer of material.

Abstract: An innovative wing structure provides ribs to support skin panels without an attachment between the rib and the stringer free flange or the web. The support is provided by rib shear ties installed directly to the stringer skin flange. The rib incorporates a cut away to allow the stringer to pass through the rib. The composite stringer is an ‘I’ section and is stable under compression, not requiring mechanical methods to prevent rolling over.

Abstract: A structure for use on an aircraft and a method of manufacturing said structure. The structure comprises first and second structural elements and a fastening device. The fastening device comprises a bolt that engages with a barrel nut. The first structural element is arranged, in use, to bear loads that are predominantly in a direction that is generally coplanar with the axis of the elongate member. The elongate member extends through the second structural element and ends inside the first structural element.

Abstract: An aerofoil, particularly a helicopter main rotor blade has a leading edge protector comprising a strip of resilient polymer, preferably polyurethane, adhered to the leading edge of the flex section of the blade.

Abstract: It is an object to provide a blade member for an airplane which is simple in structure, and moreover is excellent with respects to weight, aerodynamic performance, cost, strength and durability. A vane of a double-slotted flap includes: an outer skin area surrounded by a first outer skin, a second outer skin, a leading edge and a trailing edge each having a predetermined wall thickness. Front and rear reinforcing areas are provided that extend in a span direction within the outer skin area and are connected to the first outer skin and the second outer skin. The outer skin area and the reinforcing areas are integrally formed by wire electrical discharge-machining. The first outer skin and the second outer skin respectively have thickened portions thicker than the other portions, and the trailing edge is formed to have a thickness which is approximately zero. This blade member can be simplified in structure, leading to reductions in the number of parts, number of assembling steps and weight.