REINFORCING COMPONENT FOR A STRUCTURE OF AN AIRCRAFT OR SPACECRAFT, AIRCRAFT OR SPACECRAFT, AND METHOD

Abstract

A reinforcing component for a structure of an aircraft or spacecraft has a first component region for reinforcing at least one other element, and at least one second component region, which is permanently connected to the first component region. The reinforcing component is formed using a thermoplastic plastics material in each of the first component region and the second component region. In the first component region, the thermoplastic plastics material forms a matrix in which continuous reinforcing fibres are embedded. In the second component region, the reinforcing component comprises discontinuous reinforcing fibres or is free of reinforcing fibres.

Claims

1. A reinforcing component for a structure of an aircraft or spacecraft, comprising: a first component region, which is elongate, for reinforcing at least one other element; and at least one second component region, which is permanently connected to the first component region, the reinforcing component being formed using a thermoplastic plastics material in each of the first component region and the second component region; in the first component region, the thermoplastic plastics material forming a matrix in which continuous reinforcing fibres are embedded; and in the second component region, the reinforcing component comprising discontinuous reinforcing fibres or being free of reinforcing fibres.

2. The reinforcing component of claim 1, wherein the first component region and the second component region are produced by separately providing a first component element and a second component element and by subsequently welding the second component element to the first component element.

3. The reinforcing component of claim 2, wherein the second component element is injection-moulded.

4. The reinforcing component of claim 1, wherein the first component region and the second component region are produced by providing a first component element and subsequently spraying the second component region on by injection moulding.

5. The reinforcing component of claim 1, wherein short or long fibres are embedded in the thermoplastic plastics material as reinforcing fibres in the second component region.

6. The reinforcing component of claim 1, wherein the reinforcing component is formed as a former or a former element.

7. The reinforcing component of claim 1, wherein the second component region is formed and arranged for one or more of reinforcing the first component region at least in portions and stabilising the first component region against tilting at least in portions.

8. The reinforcing component of claim 1, wherein the first component region is formed with a web and with a flange connected to the web, and the second component region for reinforcing the web is arranged orientated transverse to the web and the flange in the manner of a rib.

9. The reinforcing component of claim 8, wherein the first component region further comprises a foot region connected to the web for coupling the reinforcing component to a skin portion, the second component region being permanently connected to the foot region and the web and bracing the web against the foot region.

10. The reinforcing component of claim 1, wherein the second component region is formed as a belt permanently connected to the first component region.

11. The reinforcing component of claim 1, wherein the second component region is provided with at least one means for attaching cabin components or systems or forms a holding means for cabin components or systems.

12. The reinforcing component of claim 1, wherein the reinforcing component comprises a plurality of second component regions.

13. The reinforcing component of claim 1 wherein the first component region is elongate.

14. An aircraft or spacecraft comprising a reinforcing component, the reinforcing component comprising: a first component region, which is elongate, for reinforcing at least one other element, and at least one second component region, which is permanently connected to the first component region; the reinforcing component being formed using a thermoplastic plastics material in each of the first component region and the second component region; in the first component region, the thermoplastic plastics material forming a matrix in which continuous reinforcing fibres are embedded; and in the second component region, the reinforcing component comprising discontinuous reinforcing fibres or being free of reinforcing fibres.

15. A method for manufacturing a reinforcing component for a structure of an aircraft or spacecraft, the method comprising: forming and permanently interconnecting a first component region for reinforcing at least one other element, and at least one second component region; forming the reinforcing component using a thermoplastic plastics material in each of the first component region and the second component region; forming, in the first component region, a matrix in which continuous reinforcing fibres are embedded from the thermoplastic plastics material; and forming, in the second component region, the reinforcing component with discontinuous reinforcing fibres or free of reinforcing fibres.

16. The method of claim 15, wherein, to produce the first and second component regions, a first component element and a second component element are provided separately and subsequently welded together.

17. The method of claim 15, wherein, to produce the first and second component regions, a first component element is provided and the second component region is produced by spraying the second component region on in an injection moulding method.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] The present invention is described in greater detail in the following by way of the embodiments set out in the schematic drawings, in which:

[0041] FIG. 1 is a perspective view of an aeroplane in which reinforcing components in accordance with embodiments of the invention may be used;

[0042] FIG. 2 is a side view of the aeroplane of FIG. 1;

[0043] FIG. 3 shows a reinforcing component, formed as a former, in accordance with a first embodiment, together with an example skin element of a fuselage skin;

[0044] FIG. 4 is a schematic sectional view A-A of the reinforcing component of FIG. 3;

[0045] FIG. 5 shows a sub-region of the reinforcing component of FIG. 3, again in the section A-A, in accordance with a variant of the first embodiment;

[0046] FIG. 5A is a perspective view of a sub-region of the reinforcing component of FIG. 3 in a further variant of the first embodiment;

[0047] FIG. 6 shows a reinforcing component formed as a former in accordance with a second embodiment of the invention; and

[0048] FIG. 7 is a schematic sectional view B-B of the reinforcing component of FIG. 6.

[0049] The accompanying drawings are intended to provide a further understanding of the embodiments of the invention. They illustrate embodiments, and are intended to explain principles and concepts of the invention in connection with the description. Other embodiments and many of the stated advantages can be seen from the drawings. The elements of the drawings are not necessarily to scale.

[0050] In the drawings, unless specified otherwise, like, functionally equivalent and equivalently acting elements, features and components are provided each with like reference numerals.

DETAILED DESCRIPTION

[0051] FIGS. 1 and 2 show an aircraft in the form of a passenger aeroplane 1, which comprises a fuselage 2, aerofoils 3 and tail units 5 and 7. Reinforcing components in accordance with the embodiments of the invention disclosed in the following with reference to FIGS. 3 to 7 may be used in the aeroplane 1 of FIGS. 1 and 2.

[0052] A first embodiment of a reinforcing component 11 formed as a former for a fuselage structure of the aeroplane 1 of FIG. 1, 2 is shown schematically in portions in FIG. 3.

[0053] The reinforcing component 11 of FIG. 3 comprises a first component region 13 and a plurality of second component regions 17, merely a portion of the reinforcing component 11 comprising two second component regions 17 being shown in FIG. 3 for reasons of clarity. For illustrative purposes, the two second component regions 17 are each enclosed in a dashed line in FIG. 3. The second component regions 17 are formed identically in the first embodiment.

[0054] The first component region 13 is of an elongate shape curved along a longitudinal direction L of the reinforcing component 11, and extends in the aeroplane 1 in the peripheral direction U of the fuselage 2. A function of the first component region 13 is to reinforce a skin portion 19 of a fuselage skin 23 of the fuselage 2. For this purpose, the first component region 13 comprises a web 14 and a flange 15 integrally connected to the web 14, the web 14 and the flange 15 extending along the longitudinal direction L of the reinforcing component 11 in the peripheral direction U of the fuselage 2. The first component region 13 further comprises foot regions 16 integrally connected to the web 14 for coupling the reinforcing component 11 to the skin portion 19. Further, on the side facing the skin portion 19, the first component region 13 comprises clearances 29, for example for passing stringers (not shown in the drawing) through as further reinforcing elements for the skin portion 19.

[0055] The second component regions 17 are each formed as a wall-like region having a substantially triangular basic shape, and are each permanently connected to one of the foot regions 16 and to the web 14. In this way, the two component regions 17 brace the first component region 13, and in particular the web 14, against the foot regions 16, reinforcing and stabilising the web 14, for example against tilting. For this purpose, the second component regions 17 are orientated transverse to the web 14, transverse to the foot region 16 and transverse to the flange 15 in the manner of ribs; see also the sectional view of FIG. 4. In particular, in the embodiment shown, each of the second component regions 17 extends transverse to the longitudinal direction L of the reinforcing component 11, and in particular substantially perpendicular to the web 14 and the foot region 16, as a wall-like element.

[0056] In the reinforcing component 11 of FIG. 3, the first and second component regions 13 and 17 are permanently interconnected. FIG. 3 shows that each of the two component regions 17 is rigidly connected to the web 14 in a first connection region 18a and to the associated foot region 16 in a second connection region 18b.

[0057] The reinforcing component 11 of the first embodiment is an integral fibre composite component of a hybrid design, the reinforcing component 11 being formed using a thermoplastic plastics material both in the first component region 13 and in the second component region 17. The same thermoplastic plastics material may be used for the first and second component regions 13 and 17, or it may be provided that the thermoplastic plastics material in the first component region 13 is different from the thermoplastic plastics material in the second component regions 17.

[0058] In the first component region 13, the thermoplastic plastics material forms a matrix in which continuous reinforcing fibres are embedded. Some of these reinforcing fibres are denoted by reference numeral 31 in FIG. 3 by way of example. Continuous reinforcing fibres may also be referred to as “endless” fibres. Continuous fibres of this type are carefully arranged in a targeted manner in such a way that the first component region 13 acquires the desired mechanical properties. The reinforcing fibres 31 may in particular be arranged in such a way that they can absorb the incoming loads as well as possible. It will be appreciated that the fibres 31 schematically illustrated in FIG. 3 are merely to be understood as an example, and that reinforcing fibres or bundles of reinforcing fibres may be provided in various orientations and arrangements within the first component region 13, depending on the expected load on the reinforcing component 11. The continuous fibres 31 have a targeted arrangement and orientation within the first component region 13 for this purpose, and may extend as “endless” fibres for example from one end to the other of the reinforcing component 11. The reinforcing fibres 31 may for example be carbon fibres, glass fibres or other suitable reinforcing fibres or combinations thereof.

[0059] The second component regions 17 may be formed free of reinforcing fibres using a thermoplastic plastics material. In advantageous and preferred variants of the first embodiment, however, the thermoplastic plastics material of the second component regions 17 forms a matrix, in which discontinuous reinforcing fibres, shown schematically by way of example in FIG. 4 and denoted by reference numeral 37, are embedded. The discontinuous reinforcing fibres 37 are preferably short or long fibres. In particular, reinforcing fibres 37 formed as short fibres may be of a length of up to approximately 1 mm, or reinforcing fibres 37 formed as long fibres may be of a length of up to approximately 50 mm.

[0060] The reinforcing fibres 37 in the second component regions 17 may also be carbon fibres, glass fibres or other suitable fibres or combinations thereof.

[0061] The reinforcing fibres 31 in the first component region 13 and the reinforcing fibres 37 in the second component region 17 may be formed using the same material or using different materials. In an advantageous variant of the first embodiment, the second component regions 17 may each have glass fibres as reinforcing fibres 37, whilst the continuous reinforcing fibres 31 of the first component region 13 are carbon fibres. In another variant, the fibres 31 and the fibres 37 may be carbon fibres in each case.

[0062] To manufacture the reinforcing component 11 in accordance with the first embodiment, shown in FIG. 3, initially a first component element 43 for forming the first component region 13 is provided. The first component element 43 may for example be manufactured by way of a deformation process and optionally a subsequent solidification from a planar semi-finished product, which contains a thermoplastic plastics material as a matrix and a reinforcing fibre arrangement. In cross section, the first component element 43 (see FIG. 4) may for example form a C-shaped profile having limbs of different lengths, the lower leg of the C-shape in FIG. 4 forming a skin-side flange of the component element 43. To form the foot regions 16 and the clearances 29, the component element 43 may for example be processed further after the C-shaped basic shape thereof is produced, or the clearances 19 are provided by corresponding shaping actually during the formation of the first component element 43. In the embodiment shown, the first component element 43 may be considered a type of “base former” or base part for the former 11. In FIG. 3, the foot portions 16 form flange-like portions of the first component region 13, which are integrally connected to the web 14.

[0063] To produce the second component regions 17, a plurality of identical second component elements 47 are manufactured by injection moulding, the second component elements 47 initially still being present as separate elements after the injection moulding. The second component elements 47 are thus injection moulded from the thermoplastic plastics material, containing the discontinuous fibres 37, for the second component region 17. Standardising the second component elements 47 and the injection moulding thereof makes possible expedient manufacture thereof even for a relatively complex geometry.

[0064] After the second component elements 47 are manufactured separately, they are welded to the first component element 43 to manufacture the reinforcing component 11 of FIG. 3. For this purpose, the first and/or second component element 43, 47 may preferably be heated locally to a suitable temperature and the component elements 43, 47 subsequently joined together. The welding subsequently takes place in the connection regions 18a,b. The component elements 43, 47 may for example already be positioned relatively to one another by a suitable device prior to heating. Preferably, the component elements 43, 47 are held against one another under pressure by regions of the relevant thermoplastic matrix which have melted or at least sufficiently softened during heating until sufficient solidification takes place.

[0065] Thus, by using thermoplastic plastics materials for the first and second component elements 43, 47, as disclosed above, it is advantageously possible to weld each of the second component elements 47 to the first component element 43. A reliable, permanent connection of the component elements 43 and 47 is thus achieved, and a unitary reinforcing component 11 comprising the first and second component regions 13 and 17 is formed. Additional connecting elements such as rivets or bolts are not required, and this saves costs and operating time. Instead, the reinforcing component 11 of FIG. 3 may be produced as an integral former having a relatively complex geometry in an advantageous, simple and cost-effective method.

[0066] In a variant, the reinforcing component 11 of FIG. 3 may be manufactured in such a way that initially the first component element 43 is provided as disclosed above and second component regions 17 are subsequently sprayed on by injection moulding. For this purpose, the first component element 43 may be laid in a suitable mould which has additional, suitably shaped cavities for casting the second component regions 17. Subsequently, the second component regions 17 are cast on by injection moulding, a thermoplastic matrix having discontinuous reinforcing fibres 37 contained therein again being used. In this overmoulding, the second component regions 17 are likewise permanently and reliably connected to the first component region 13, without rivets or bolts being required as additional connecting elements.

[0067] FIGS. 3 and 4 further show that the second component regions 17 are each provided with a means 53 for attaching cabin components and/or systems. Thus in an advantageous manner which reduces weight and outlay, a holding function is also integrated into the second component region 17 and thus into the reinforcing component 11 formed as a fuselage former. This may for example facilitate fastening cabin or system components in a manner orientated towards the formers. The means 53 may form a hard point for this purpose.

[0068] FIG. 3 further schematically shows that in the first embodiment the means may be formed using a sleeve 57, which may be substantially cylindrical, comprising a through-opening 58. So as further to facilitate attaching the cabin components or systems, the first component region 13 is formed in the region of the web 14 for example with a through-opening 59 orientated with respect to the through-opening 58, for example concentric (see FIG. 4). Alternatively, the through-opening 59 may be omitted and the opening 58 may be formed in the manner of a blind hole.

[0069] In a variant shown schematically in FIG. 5 of the first embodiment, a metal socket 61 is integrated into the second component region 17. For this purpose, in the variant of FIG. 5, the metal socket 61 is enclosed peripherally with the thermoplastic plastics material comprising added discontinuous fibres by overmoulding it in an injection moulding or spraying process. In this way, the metal socket 61 is enclosed by a sleeve-like portion 67 in the peripheral direction thereof, and thus held securely and reliably in the second component region 17. The metal socket 61 may for example be used for fastening the cabin components or systems, and thus forms the fastening means 53 or at least part thereof. In variants, the internal thread 62 may be omitted or replaced with other fastening or connection means suitable for air or space travel.

[0070] Alternatively or additionally, in variants it may be provided that a means 53 without a reinforcing function for the web 14 is permanently connected to the first component region 13 and thus for example to the web 14, for example by welding or spraying on as disclosed above. In a variant of this type, the second component region 17 may itself form a holding means for cabin components and/or systems. A variant of this type of the first embodiment is shown schematically by way of example in FIG. 5A, other embodiments being conceivable.

[0071] In the first embodiment, in which further components can be attached to the former 11 using the means 53, it may be found to be advantageous to use continuous carbon fibres in the first component region 13 and to use discontinuous glass fibres in the second component regions 17. The components (not shown in the drawings) attached using the means 53 may for example be made of metal materials, for example aluminium. Whilst the carbon fibres 31 provide the desired mechanical load capacity in the first component region 13, the glass fibres 37 in the second component region 17 reduce or prevent the electric conductivity of this component region. When metal components are attached using the means 53, the occurrence of galvanic corrosion is thus advantageously prevented or inhibited.

[0072] The foot regions 16 are for coupling the reinforcing component 11 to another element, in particular to the skin portion 19 to be reinforced. For this purpose, the foot portions 16 may for example be connected directly or indirectly to an inner face of the skin portion 19, in particular by riveting or by means of bolts. However, other types of connection of the foot regions 16 to the skin portion 19 are conceivable instead. In a preferred variant, the skin portion 19 may also be formed with a thermoplastic plastics material as a matrix and with reinforcing fibres, such as carbon fibres, embedded in the thermoplastic plastics material, for example with the help of a suitable semi-finished product. On the finished skin portion 19, which has for example been solidified under pressure by squeeze moulding, made of a thermoplastic fibre composite material, the reinforcing component 11 can be welded onto the inside of the skin portion 19 as a former, the thermoplastic plastics material of the skin portion 19 and/or of the foot region 16 softening or melting and reliable connection of the reinforcing component 11 and the skin portion 19 being achieved by resolidification.

[0073] FIGS. 6 and 7 schematically show a second embodiment of the invention. The above statements are applicable analogously to the embodiment of FIGS. 6 and 7, the differences from the first embodiment being disclosed in the following.

[0074] In the second embodiment, the second component region 17 is formed as an additional flange or belt 71, which is permanently connected to the first component region 13 so as to form a reinforcing component 11. The belt 71 may in particular be welded on or sprayed on, and contains a thermoplastic plastics material which preferably contains discontinuous reinforcing fibres.

[0075] To manufacture the reinforcing component 11 in accordance with the embodiment of FIG. 6, 7, which again is a former for an aeroplane fuselage, a first component element 43 is initially formed from a planar semi-finished product, for which purpose the semi-finished product is brought into a geometry substantially Z-shaped in cross section (see FIG. 7) and comprising a web 14. Flanges are attached to the two ends of the web 14, foot regions 16 being formed from the lower flange in FIG. 7 and it being possible for the flange 15 to be present continuously along the longitudinal direction of the reinforcing component 11 (see FIG. 6).

[0076] The Z-shaped cross-sectional geometry of the first component element 43, which forms the first component region 13 in FIG. 6, 7, is supplemented with the additional belt 71 as a second component region 17. The belt 71 is provided in addition to the flange 15, and contributes to fulfilling the mechanical function of the reinforcing component 11. Because the belt 71 is formed using discontinuous reinforcing fibres and connected to the first component region 13 by spraying on or welding on in a connection region 18c, the manufacture of a reinforcing component 11 comprising two belts or flanges 71, 15 (see FIG. 7) is greatly simplified. In particular, the first component region 13 can be formed in a simple manner at low outlay using a planar semi-finished product and for example subsequent solidification. In variants of the second embodiment, the belt 71 may alternatively be arranged on the web 14 at a different height from the flange 15 with respect to the foot region 16.

[0077] In all above-disclosed embodiments, the thermoplastic plastics material in the first component region 13 may be different from the thermoplastic plastics material in the second component regions 17, in particular in terms of the associated melting temperature and/or glass transition temperature thereof. In this way, the melting or softening properties of the thermoplastic plastics materials can be influenced in a more targeted manner during the welding or spraying-on process. However, in all above-disclosed embodiments, it is conceivable for the first and second component regions 13, 17 to use the same thermoplastic plastics material.

[0078] In the above-described embodiments, for example high-grade thermoplastics, such as semi-crystalline thermoplastics, are used as the thermoplastic plastics materials in the first and/or second component regions 13, 17, for example a polyaryletherketone (PAEK), a polyetheretherketone (PEEK) or the like.

[0079] Although the present invention was fully disclosed above by way of preferred embodiments, it is not limited thereto, but can be modified in numerous ways.

[0080] In particular, the hybrid design for the reinforcing component may be of use not only in formers, but also in other reinforcing components, in particular for aircraft or spacecraft.

[0081] While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.