AIRFRAME AND METHOD OF MANUFACTURING AN AIRFRAME

Abstract

An airframe or a part thereof 3, for example a skin assembly or a profile such as a structural profile, comprises: a wall W having an aperture A therethrough, wherein the wall W provides a frame F surrounding, at least in part, the aperture A; a panel P conforming with the aperture A; and wherein the airframe or the part 3 thereof is configurable in: a first configuration, wherein the panel P and the frame F are mutually spaced apart; and a second configuration, wherein the panel P is received in the frame F and wherein the frame F resists movement of the panel P in two or three mutually orthogonal directions.

Claims

1. An airframe or a part thereof, for example a skin assembly or a profile such as a structural profile, wherein the airframe or part thereof comprises: a wall having an aperture therethrough, wherein the wall provides a frame surrounding, at least in part, the aperture; a panel conforming with the aperture; and wherein the airframe or the part thereof is configurable in: a first configuration, wherein the panel and the frame are mutually spaced apart; and a second configuration, wherein the panel is received in the frame and wherein the frame resists movement of the panel in two or three mutually orthogonal directions.

2. The airframe or the part thereof according to claim 1, wherein the frame defines a female coupling member and wherein the panel defines a mating male coupling member.

3. The airframe or the part thereof according to claim 1, wherein the frame includes a first shoulder, wherein the panel includes a second shoulder and wherein respective surfaces of the first shoulder and the second shoulder confront and/or contact in the second configuration.

4. The airframe or the part thereof according to claim 1, comprising a set of coupling fasteners, preferably releasable fasteners, arranged to mutually fasten the frame and the panel in the second configuration.

5. The airframe or the part thereof according to claim 1, wherein respective thicknesses of the skin and of the panel are substantially similar.

6. The airframe or the part thereof according to claim 1, wherein the wall and the panel comprise a composite material or a plurality thereof.

7. A method of assembling an airframe or the part thereof, comprising: providing an airframe or a part thereof, for example a skin assembly or a profile such as a structural profile, wherein the airframe or part thereof comprises: a wall having an aperture therethrough, wherein the wall provides a frame surrounding, at least in part, the aperture; a panel conforming with the aperture; and wherein the airframe or the part thereof is configurable in: a first configuration, wherein the panel and the frame are mutually spaced apart; and a second configuration, wherein the panel is received in the frame and wherein the frame resists movement of the panel in two or three mutually orthogonal directions; and receiving the panel in the frame, wherein the frame resists movement of the panel in two or three mutually orthogonal directions.

8. The method of assembling the airframe or the part thereof according to claim 7, wherein the step of receiving the panel in the frame configures the airframe or the part thereof in the second configuration.

9. The method of assembling the airframe or the part thereof according to claim 8, further comprising: mutually spacing apart the panel and the frame, thereby arranging the airframe or the part thereof in the first configuration.

10. The airframe or part thereof comprising a set of modular cells, including a first cell comprising a set of profiles including: a first structural profile, having a first length and enclosing a first volume providing a first passageway; and a second profile, having a second length and enclosing a second volume, wherein the first passageway is arranged to receive the second profile therein; wherein the first structural profile is according to claim 1; and/or wherein the airframe or part thereof comprises a skin assembly according to claim 1, arranged to surround, at least in part, the first cell.

11. The airframe or part thereof according to claim 10, wherein the skin assembly is removable from the airframe.

12. A method of manufacturing an airframe or a part thereof, for example a skin assembly or a profile such as a structural profile, wherein the airframe or part thereof comprises a wall having an aperture therethrough and a panel conforming with the aperture, the method comprising: stacking a set of layers, including a first layer comprising a first composite material precursor and a second layer comprising a second composite material precursor, wherein stacking the set of layers comprises including a release sheet between the first layer and the second layer; curing the first composite material precursor and the second composite material precursor of the stacked first layer and the second layer, thereby providing a first composite material and a second composite material therefrom, respectively; separating the stacked first layer and the second layer, wherein the first layer and the second layer comprise the first composite material and the second composite material, respectively; removing the release layer from between the separated first layer and the separated second layer; excising a first portion and a correlated second portion respectively from the separated first layer and from the separated second layer, thereby providing therein respectively a first passageway and a correlated second passageway; restacking and mutually coupling the set of layers, thereby providing the airframe or the part thereof, wherein restacking and mutually coupling the set of layers comprises: restacking the first layer and the second layer having therein respectively the first passageway and the correlated second passageway and mutually coupling the restacked first layer and second layer, thereby providing the wall, wherein the wall has an aperture therethrough provided by the first passageway and the correlated second passageway and wherein the wall provides a frame surrounding, at least in part, the aperture; restacking the excised first portion and the correlated second portion and mutually coupling the restacked excised first portion and the correlated second portion, thereby providing a panel corresponding to the aperture.

13. The method according to claim 12, comprising providing the first layer and/or the second layer, at least in part, by fibre placement, braiding, knitting and/or weaving.

14. The method according to claim 12, wherein excising the first portion and the correlated second portion respectively from the separated first layer and from the separated second layer comprises thermal cutting, for example laser cutting, plasma cutting or electron beam cutting.

15. The method according to claim 12, wherein a first gap, for example a boundary or interface gap, between the excised first portion and the first passageway in the first layer is at most 500 μm, preferably at most 250 μm, more preferably at most 125 μm, most preferably at most 50 μm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0170] For a better understanding of the invention, and to show how exemplary embodiments of the same may be brought into effect, reference will be made, by way of example only, to the accompanying diagrammatic Figures, in which:

[0171] FIG. 1 schematically depicts an airframe or part thereof according to an exemplary embodiment;

[0172] FIG. 2 schematically depicts a rear perspective view of the airframe or part thereof of FIG. 1, in more detail;

[0173] FIG. 3 schematically depicts a front perspective view of the airframe or part thereof of FIG. 1, in more detail;

[0174] FIG. 4 schematically depicts a side elevation of the airframe or part thereof of FIG. 1, in more detail;

[0175] FIGS. 5A-5D schematically depict transverse cross-sections of airframes or parts thereof according to exemplary embodiments;

[0176] FIGS. 6A-6B schematically depict transverse cross-sections of airframes or parts thereof according to exemplary embodiments;

[0177] FIG. 7 schematically depicts a method of assembling an airframe or part thereof according to an exemplary embodiment;

[0178] FIGS. 8A-8B schematically depict perspective views of a watercraft frame or parts thereof according to exemplary embodiments.

[0179] FIG. 9 schematically depicts an airframe or part thereof according to an exemplary embodiment, configured in a first configuration;

[0180] FIG. 10 schematically depicts the airframe or the part thereof of FIG. 9, configured in a second configuration;

[0181] FIG. 11 schematically depicts the airframe or the part thereof of FIG. 9, configured in the first configuration;

[0182] FIG. 12 schematically depicts a wall of the airframe or the part thereof of FIG. 9, in more detail;

[0183] FIG. 13 schematically depicts a panel of the airframe or the part thereof of FIG. 9, in more detail;

[0184] FIG. 14 is a photograph of an airframe or part thereof according to an exemplary embodiment, during manufacture;

[0185] FIG. 15 is a photograph of an airframe or part thereof according to an exemplary embodiment, during manufacture;

[0186] FIG. 16 is a photograph of an airframe or part thereof according to an exemplary embodiment;

[0187] FIG. 17 schematically depicts an airframe or part thereof according to an exemplary embodiment, configured in a first configuration;

[0188] FIG. 18 schematically depicts the airframe or part thereof of FIG. 17, configured in a second configuration;

[0189] FIG. 19 schematically depicts the airframe or part thereof of FIG. 17, configured in a first configuration; and

[0190] FIG. 20 schematically depicts the airframe or part thereof of FIG. 17, configured in a second configuration.

DETAILED DESCRIPTION OF THE DRAWINGS

[0191] FIG. 1 schematically depicts an airframe 1 or part thereof according to an exemplary embodiment. FIG. 2 schematically depicts a rear perspective view of the airframe 1 or part thereof of FIG. 1, in more detail. FIG. 3 schematically depicts a front perspective view of the airframe 1 or part thereof of FIG. 1, in more detail. FIG. 4 schematically depicts a side elevation of the airframe 1 or part thereof of FIG. 1, in more detail.

[0192] The airframe 1 or part thereof comprises a set of modular cells 10, including a first cell 10A comprising a set of profiles 100 including: a first structural profile 100A, having a first length L1 and enclosing a first volume V1 providing a first passageway P1; and a second profile 1006, having a second length L2 and enclosing a second volume V2, wherein the first passageway P1 is arranged to receive the second profile 100B therein.

[0193] In this example, the airframe 1 or part thereof comprises and/or provides the fuselage (i.e. an aircraft's main body section). In this example, the airframe 1 or part thereof does not comprise and/or provide the wings.

[0194] In this example, the set of modular cells 10 includes 4 modular cells 10A, 10B, 10C, 10D. In this example, the 4 modular cells 10 are each as described with respect to the first cell 10A.

[0195] The first cell 10A comprises the set of profiles 100, including the first structural profile 100A and the second profile 100B.

[0196] In this example, the first structural profile 100A is arranged to provide, at least in part, the structure of the airframe 1 and to resist, at least in part, internal and/or external forces in one, two or three dimensions. In this example, the first structural profile 100A has a constant cross sectional shape and/or dimension (generally, for example, cross-sectional width, height, diameter and/or area) along the first length L1. In this example, the first structural profile 100A is an outer profile, or example the outermost profile, having an external surface, exposed to the ambient, for example. In this example, the first structural profile 100A partially surrounds the first volume V1, comprising an access port.

[0197] In this example, the second profile 100B does not comprise and/or is not a structural profile. In this example, an external shape and/or dimension of the second profile 100B corresponds with an internal shape and/or dimension of the first structural profile 100A i.e. of the first passageway P1. In this example, the second profile 100B has a constant cross sectional shape and/or dimension along the second length L2. In one example, the second profile 100B is an inner profile, or example the innermost profile, not having an external surface exposed to the ambient, for example. In this example, the second profile 100B comprises one or more wall portions having no perforations therethrough, for example providing a sealable enclosure for the second profile 100B.

[0198] In this example, the first passageway P1 is arranged to fully (i.e. completely) receive the second profile 100B therein. In this example, the first structural profile comprises an aperture, for example an access door such as at an end thereof, arranged to receive the second profile 100B therethrough.

[0199] In this example, the first passageway P1 is arranged to slidably receive the second profile 100B therein.

[0200] In this example, the first passageway P1 comprises no bulkheads therein. More generally, in this example, the first passageway P1 comprises no obstructions.

[0201] In this example, an external shape, preferably cross-sectional shape and/or dimension, of the second profile 100B corresponds with, for example is the same as, an internal shape, preferably cross-sectional shape and/or dimension, of the first structural profile (i.e. of the first passageway P1).

[0202] In this example, the second volume V2 is configured to comprise and/or comprises a propulsor, a fuel tank, electronics for a control system, surveillance equipment, munitions and/or part thereof.

[0203] In this example, the airframe 1 or part thereof is arrangeable in:

[0204] a first arrangement, wherein the second profile 100B is received (i.e. inserted) in the first passageway P1; and

[0205] a second arrangement, wherein the second profile 100B is removed from the first passageway P1.

[0206] In this example, the airframe 1 or part thereof is repeatedly arrangeable in the first arrangement and in the second arrangement.

[0207] In this example, the set of modular cells 10 includes a second cell 10B. The second cell 10B is as described with respect to the first cell 10A.

[0208] In this example, the first cell 10A and the second cell 10B are mutually coupled. In this example, the first cell 10A and the second cell 10B are mutually coupled mechanically, for example using mechanical fasteners such as non-releasable fasteners for example non-threaded fasteners (e.g. rivets) and/or releasable fasteners for example clips, rings, toggle bolts, clamps and/or threaded fasteners (e.g. bolts and nuts).

[0209] In this example, the first cell 10A and the second cell 10B are mutually releasably coupled, for example mechanically such as using releasable mechanical fasteners.

[0210] In this example, the first cell 10A and the second cell 10B are mutually reconfigurably coupled, for example mechanically, as described above. In this example, the first cell 10A and the second cell 10B are mutually reconfigurably coupled mechanically, using releasable fasteners positioned in pre-determined positions.

[0211] In this example, the first cell 10A and the second cell 10B are mutually interlockably coupled, for example mechanically.

[0212] In this example, the set of modular cells 10 includes a third cell 10C and the first cell 10A, the second cell 10B and the third cell 10C are mutually coupled, for example as described with respect to the first cell 10A and the second cell 10B.

[0213] In this example, the airframe 1 or part thereof is configurable in:

[0214] a first configuration, wherein the first cell 10A, the second cell 10B and the third cell 10C are mutually coupled; and

[0215] a second configuration, wherein the first cell 10A and the second cell 10B are mutually coupled, wherein the first cell 10A and the third cell 10C are mutually coupled and wherein the second cell 10B and the third cell 10C are not mutually coupled.

[0216] In this example, the airframe 1 or part thereof is repeatedly configurable in the first configuration and in the second configuration. That is, the first cell 10A, the second cell 10B and the third cell 10C may be mutually coupled and uncoupled, repeatedly.

[0217] In this example, the airframe 1 or part thereof is configurable in:

[0218] a third configuration, wherein the first cell 10A and the second cell 10B are mutually coupled, wherein the second cell 10B and the third cell 10C are mutually coupled and wherein the first cell 10A and the third cell 10C are not mutually coupled.

[0219] In this example, the airframe 1 or part thereof is repeatedly configurable in the first configuration, in the second configuration and in the third configuration. That is, the first cell 10A, the second cell 10B and the third cell 10C may be mutually coupled and uncoupled, repeatedly.

[0220] In this example, an external shape, preferably cross-sectional shape, of the first structural profile 100A tessellates.

[0221] In this example, the external shape, preferably cross-sectional shape, of the first structural profile 100A comprises and/or is a hexagon.

[0222] In this example, the set of cells 10 comprises a composite material, for example a fibre reinforced composite material such as including carbon fibre. In this example, the first structural profile 100A and/or the second profile 100B comprises such a composite material.

[0223] FIGS. 5A-5D schematically depict transverse cross-sections of airframes or parts thereof according to exemplary embodiments.

[0224] In more detail, FIG. 5A schematically depicts a transverse cross-section of an airframe 5A or part thereof wherein the set of cells 10 includes 1 cell 10A.

[0225] In more detail, FIG. 5B schematically depicts a transverse cross-section of an airframe 5B or part thereof wherein the set of cells 10 includes 3 cells 10A, 10B, 10C wherein the first cell 10A and the second cell 10B are mutually coupled, wherein the first cell 10A and the third cell 10C are mutually coupled and wherein the second cell 10B and the third cell 10C are not mutually coupled.

[0226] In more detail, FIG. 5C schematically depicts a transverse cross-section of an airframe 5C or part thereof wherein the set of cells 10 includes 4 cells 10A, 10B, 10C, 10D wherein the first cell 10A and the second cell 10B are mutually coupled, wherein the first cell 10A and the third cell 10C are mutually coupled, wherein the second cell 10B and the third cell 10C are not mutually coupled, wherein the first cell 10A and the fourth cell 10D are mutually coupled, wherein the second cell 10B and the fourth cell 10D are mutually coupled and wherein the third cell 10C and the fourth cell 10D are mutually coupled.

[0227] In more detail, FIG. 5D schematically depicts a transverse cross-section of an airframe 5D or part thereof wherein the set of cells 10 includes 5 cells 10A, 10B, 10C, 10D, 10E wherein the first cell 10A and the second cell 10B are mutually coupled, wherein the first cell 10A and the third cell 10C are mutually coupled, wherein the first cell 10A and the fourth cell 10D are mutually coupled, wherein the first cell 10A and the fifth cell 10E are mutually coupled, wherein the second cell 10B and the third cell 10C are mutually coupled, wherein the fourth cell 10D and the fifth cell 10E are mutually coupled, wherein the second cell 10B and the fourth cell 10D are not mutually coupled, wherein the second cell 10B and the fifth cell 10E are not mutually coupled, wherein the third cell 10C and the fourth cell 10D are not mutually coupled and wherein the third cell 10B and the fifth cell 10E are not mutually coupled.

[0228] FIGS. 6A-6B schematically depict transverse cross-sections of airframes or parts thereof according to exemplary embodiments.

[0229] In more detail, FIG. 6A schematically depicts a transverse cross-section of an airframe 6A or part thereof wherein the set of cells 10 includes 3 cells 10A, 10B, 10C wherein the first cell 10A and the second cell 10B are mutually coupled, wherein the first cell 10A and the third cell 10C are mutually coupled and wherein the second cell 10B and the third cell 10C are mutually coupled.

[0230] In more detail, FIG. 6B schematically depicts a transverse cross-section of an airframe 6B or part thereof wherein the set of cells 10 includes 5 cells 10A, 10B, 10C, 10D, 10E wherein the first cell 10A and the second cell 10B are mutually coupled, wherein the first cell 10A and the third cell 10C are mutually coupled, wherein the first cell 10A and the fourth cell 10D are mutually coupled, wherein the first cell 10A and the fifth cell 10E are mutually coupled, wherein the second cell 10B and the third cell 10C are mutually coupled, wherein the third cell 10C and the fourth cell 10D are mutually coupled, wherein the fourth cell 10D and the fifth cell 10E are mutually coupled, wherein the second cell 10B and the fourth cell 10E are not mutually coupled, wherein the second cell 10B and the fifth cell 10E are not mutually coupled and wherein the third cell 10C and the fifth cell 10D are not mutually coupled.

[0231] FIG. 7 schematically depicts a method of assembling an airframe or part thereof according to an exemplary embodiment. Particularly, the method is of assembling an airframe or part thereof comprising a set of modular cells, including a first cell comprising a set of profiles including: a first structural profile and enclosing a first volume providing a first passageway; and a second profile, having a second length and enclosing a second volume.

[0232] At S701, the second profile is inserted into the first passageway.

[0233] The method may comprise any of the steps described herein.

[0234] FIGS. 8A-8B schematically depict perspective views of a watercraft frame 2 or part thereof according to exemplary embodiments.

[0235] The watercraft frame 2 is generally as described with respect to the airframe 1 of FIG. 1.

[0236] FIG. 9 schematically depicts an airframe or part thereof 3 according to an exemplary embodiment, configured in a first configuration. Particularly, FIG. 9 shows a perspective view of the airframe or part thereof 3, from below.

[0237] FIG. 10 schematically depicts the airframe or the part thereof 3 of FIG. 9, configured in a second configuration. Particularly, FIG. 10 shows a perspective view of the airframe or part thereof 3, from below.

[0238] FIG. 11 schematically depicts the airframe or the part thereof 3 of FIG. 9, configured in the first configuration. Particularly, FIG. 11 shows a perspective view of the airframe or part thereof 3, from above.

[0239] FIG. 12 schematically depicts a wall W of the airframe or the part thereof 3 of FIG. 9, in more detail. Particularly, FIG. 12 shows a perspective view of the wall W, from above.

[0240] FIG. 13 schematically depicts a panel P of the airframe or the part thereof 3 of FIG. 9, in more detail. Particularly, FIG. 13 shows a perspective view of the panel P, from below.

[0241] In this example, the airframe or a part thereof 3, for example a skin assembly comprises:

[0242] a wall W having an aperture A therethrough, wherein the wall W provides a frame F surrounding, at least in part, the aperture A;

[0243] a panel P conforming with the aperture A; and

[0244] wherein the airframe or the part 3 thereof is configurable in:

[0245] a first configuration, wherein the panel P and the frame F are mutually spaced apart; and

[0246] a second configuration, wherein the panel P is received in the frame F and wherein the frame F resists movement of the panel P in two or three mutually orthogonal directions.

[0247] In this example, the aperture A and the panel P have angular figure of 8 shapes.

[0248] In this example, the frame F defines a female coupling member and wherein the panel P defines a mating male coupling member.

[0249] In this example, the frame F includes a first shoulder S1 (also known as a rabbet or landing region), wherein the panel P includes a second shoulder S2 and wherein respective surfaces of the first shoulder S1 and the second shoulder S2 confront and/or contact in the second configuration.

[0250] In this example, respective thicknesses of the wall W and of the panel P are substantially similar, wherein a ratio of the respective thicknesses is 1:1.

[0251] In this example, the wall W and the panel P comprise a composite material or a plurality thereof.

[0252] In this example, the airframe or the part 2 thereof is a skin assembly and the wall W comprises and/or is a skin.

[0253] FIG. 14 is a photograph of an airframe or part thereof 4 according to an exemplary embodiment, during manufacture. Particularly, FIG. 14 shows a first layer L1 of a set of layers, as described above. The outline of the aperture A therein is shown.

[0254] FIG. 15 is a photograph of an airframe or part thereof 4 according to an exemplary embodiment, during manufacture. Particularly, FIG. 15 shows a second layer L2 of the set of layers, as described above. The outline of the aperture A therein is shown.

[0255] FIG. 16 is a photograph of an airframe or part thereof 4 according to an exemplary embodiment. The airframe or a part thereof 4 is generally as described with respect to the airframe or a part thereof 3 of FIGS. 9 to 13.

[0256] FIG. 17 schematically depicts an airframe or part thereof 5 according to an exemplary embodiment, configured in a first configuration. Particularly, FIG. 17 shows an end elevation view of the airframe or part thereof 5.

[0257] FIG. 18 schematically depicts the airframe or part thereof 5 of FIG. 17, configured in a second configuration. Particularly, FIG. 18 shows an end elevation view of the airframe or part thereof 5.

[0258] FIG. 19 schematically depicts the airframe or part thereof 5 of FIG. 17, configured in a first configuration. Particularly, FIG. 19 shows a perspective view of the airframe or part thereof 5.

[0259] FIG. 20 schematically depicts the airframe or part thereof 5 of FIG. 17, configured in a second configuration. Particularly, FIG. 20 shows a perspective view of the airframe or part thereof 5.

[0260] The airframe or part thereof 5 is generally as described with respect to FIG. 5C. In more detail, the airframe or part thereof 5 comprises a set of cells 50 including 4 cells 50A, 50B, 50C, 50D.

[0261] The first cell 50A and the fourth cell 50D, particularly the first structural profile 100A, each comprise:

[0262] a wall W having an aperture A therethrough, wherein the wall W provides a frame F surrounding, at least in part, the aperture A;

[0263] a panel P conforming with the aperture A; and

[0264] wherein the airframe or the part thereof 50A, 50D is configurable in:

[0265] a first configuration, wherein the panel P and the frame F are mutually spaced apart; and

[0266] a second configuration, wherein the panel P is received in the frame F and wherein the frame F resists movement of the panel P in two or three mutually orthogonal directions.

[0267] Although a preferred embodiment has been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims and as described above.

[0268] Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

[0269] All of the features disclosed in this specification (including any accompanying claims and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at most some of such features and/or steps are mutually exclusive.

[0270] Each feature disclosed in this specification (including any accompanying claims, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0271] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.