Structural arrangement, aircraft or spacecraft and method

The present invention pertains inter alia to a structural arrangement, comprising a box structure, a first fibre portion which extends in a first plane, a second fibre portion which extends in a second plane, the first and the second fibre portion being interconnected at a crossing point thereof, the first fibre portion comprising a first portion on one side of the crossing point and a second portion on the other side of the crossing point, the first portion being connected to a first portion of the box structure and the second portion being connected to a second portion of the box structure, the second fibre portion forming, on one side of the crossing point, an inner web inside the box structure and, on the other side of the crossing point, an outer web outside the box structure.

FIELD OF THE INVENTION

The present invention relates to a structural arrangement, to an aircraft or spacecraft and to a method for producing a structural arrangement.

BACKGROUND OF THE INVENTION

FIG. 1shows a detail of an aircraft which is generally denoted by reference numeral100. The aircraft100comprises a landing flap102.FIG. 1shows the landing flap102when viewed in the direction opposite to the flight direction of the aircraft100. The landing flap102is shown once by a dashed line, this view corresponding to the unloaded state of the landing flap. The landing flap102is also shown by way of a solid line, this corresponding to the deformed state of the landing flap owing to air loads104, which is shown in a much exaggerated manner. The landing flap102is connected by means of two flap carriages106,108to a wing110, which is indicated merely schematically. The flap carriages106,108make it possible to adjust the landing flap102in relation to the wing110from a flight position into a take-off or landing position, the take-off and landing position serving to increase the lift. In the span direction, that is to say from left to right inFIG. 1, one flap carriage106is designed as a fixed bearing and the other flap carriage108is designed as a loose bearing. The flap carriages106,108are each connected to the landing flap102via an eye-bolt connection112.

It is known to design the eye of a respective eye-bolt connection112as a fitting which is made of metal and connected, in particular riveted, to the landing flap102. For example, publication DE 10 2007 011 613 A1 shows a metal fitting for load introduction.

There is an increasing need also to produce load introduction elements, for example the above-described eye of the eye-bolt connection112, from fibre composite materials, for example carbon-fibre-reinforced plastics material (CFRP), in order to reduce further weight and assembly costs. Publication US 2010/0148008 A1 describes a load introduction element of this type made of fibre composite material.

In addition, German patent application DE 10 2009 043 103 A1 describes a fibre composite structure comprising at least three fibre composite arms extending from a branching point.

SUMMARY OF THE INVENTION

An idea of the invention is to provide an improved, fibre-compatible approach to introducing loads, in particular into box-like structures, for example landing flaps.

According to the invention, the following is provided:a structural arrangement, in particular for an aircraft or spacecraft, comprising a box structure, comprising a first fibre portion which extends in a first plane, comprising a second fibre portion which extends in a second plane which intersects the first plane, the first and the second fibre portion being interconnected at a crossing point thereof, the first fibre portion comprising a first portion on one side of the crossing point and a second portion on the other side of the crossing point, the first portion of the first fibre portion being connected to a first portion of the box structure and the second portion of the first fibre portion being connected to a second portion of the box structure, the second fibre portion forming, on one side of the crossing point, an inner web inside the box structure and, on the other side of the crossing point, an outer web outside the box structure, comprising a supporting element which is connected to the inner web, and comprising an attachment point for introduction of a first load into the outer web, the second fibre portion guiding the first load which is introduced at the attachment point from the attachment point into the supporting element, and the first fibre portion simultaneously transferring a second load between the first and the second portion of the box structure;in addition, an aircraft or spacecraft comprising the structural arrangement according to the invention;in addition, a method for producing a structural arrangement, in particular the structural arrangement according to any of the preceding claims, in particular in the aviation or aerospace industry, comprising the following steps: providing a box structure, providing a first fibre portion which extends in a first plane, providing a second fibre portion which extends in a second plane which intersects the first plane, interconnecting the first and the second fibre portion at a crossing point thereof, connecting a first portion of the first fibre portion on one side of the crossing point to a first portion of the box structure and connecting a second portion of the first fibre portion on the other side of the crossing point to a second portion of the box structure, the second fibre portion forming, on one side of the crossing point, an inner web inside the box structure and, on the other side of the crossing point, an outer web outside the box structure, connecting the inner web to a supporting element and providing an attachment point for introduction of a first load into the outer web, the second fibre portion guiding the first load which is introduced at the attachment point from the attachment point into the supporting element, and the first fibre portion simultaneously transferring a second load between the first and the second portion of the box structure.

The idea on which the present invention is based is that the second fibre portion guides a first load from the attachment point into the supporting element, and the first fibre portion simultaneously transfers a second load between the first and the second portion of the box structure. As a result, load paths which are substantially mutually independent can be provided. The first load path passes through the crossing point in the first plane and the second load path passes through the crossing point in the second plane, without the load paths influencing each other significantly. This is advantageous particularly with regard to application in the landing flap described at the outset. The loads acting in the eye are guided in the second plane into a supporting element, for example into a rib connected to the box structure, while bending loads to which the landing flap is subjected in operation owing to the active air loads are transferred in the first plane (in particular inside the outer wall of the box structure) through the crossing point between the first and the second portion of the box structure. This results in a high loading capacity of the attachment point, it being possible to avoid in particular peeling of the eye including corresponding fibre layers.

The application of the structural arrangement is not limited to the aviation or aerospace industry. For example, said arrangement can also be applied in bridges, multi-story buildings, masts, roofs or other plane load-bearing structures.

In the present case, “fibre portion” always refers to a portion of a single fibre.

In the present case, the feature that “the first and the second fibre portion are interconnected at a crossing point thereof” includes different cases.

Said portions can be two fibre portions of different fibres which are interconnected, for example adhesively bonded or sewn to each other or interwoven, at the crossing point.

Alternatively, the first and the second fibre portion each form part of the same fibre, which extends in both the first plane and the second plane. This extension in the first and the second plane can be achieved for example by 3D weaving, as will be described in detail below.

Advantageous configurations of the invention are set out in the dependent claims.

Obviously, a plurality of first and second fibre portions can be provided.

The box structure is preferably substantially closed. “Substantially closed” means that the box structure has no or only comparatively small openings in its outer walls.

According to a further configuration of the structural arrangement according to the invention, the first and the second fibre portion are part of the same fibre. By this is meant the above-described configuration in which the fibre comprising the first and the second fibre portion extends in the first and the second plane. This results in advantages in terms of production when constructing a corresponding fibre preform. The common fibre is also anchored better than two individual fibres and therefore has a higher loading capacity.

According to a further configuration of the structural arrangement according to the invention, the first and the second fibre portion are part of different fibres. By this is meant the above-described configuration in which the different fibres are interconnected at the crossing point.

According to a further configuration of the structural arrangement according to the invention, the fibre is interwoven with other fibres in two and a half or three dimensions. The structural arrangement or a corresponding fibre preform can be produced easily as a result. Weaving in three dimensions is basically known, as described for example in U.S. Pat. No. 3,818,951. The terms “2D weaving” (that is to say, weaving in two dimensions), “2.5D weaving” (that is to say, weaving in two and a half dimensions) and “3D weaving” (that is to say, weaving in three dimensions) are distinguished from each other below.

2D weaving denotes the process of producing a planar, textile product from filamentary or fibrous semi-finished material. The finished product is referred to as a “woven fabric”. Two groups of threads are involved, which are oriented at right angles to each other, substantially in one plane (for example XY plane): what are known as the “warp threads” and, substantially at right angles thereto, what are known as the “weft threads”. The warp threads are all arranged mutually parallel for example in the Y direction and are tensioned by a suitable device. In addition, in 2D weaving the warp threads are in turn divided into two groups, the first, third, fifth, etc. thread being assigned to a warp thread group A and the second, fourth, sixth, etc. thread being assigned to a second warp thread group B. The warp threads of one warp thread group A, B in turn are fed through a device (in particular a frame, which is known as the “heald frame”, with the “healds” contained therein), which makes it possible to move all the threads of one warp thread group A, B up and down together in a direction Z oriented perpendicular to the XY plane. The movements of the two warp thread groups A, B are positively coupled in opposite directions. If the warp threads of warp thread group A are moved downwards, the threads of warp thread group B are moved upwards and vice versa. Owing to the movement in opposite directions of the two warp thread groups in the Z direction, the warp threads of each warp thread group A, B form an upper and a lower limit of an intermediate space between the warp threads, which is referred to as a “shed”. The movement of each of the warp thread groups is calculated such that the shed is large enough for a weft thread to be guided through the shed substantially in the X direction by means of a further device. This can be done for example manually by what is known as a “shuttle” or in a mechanised manner by a gripper or an air or water jet. After insertion of the weft thread, the positions of the warp thread groups A, B are switched. The warp thread group which forms the lower limit of the shed is moved upwards and the upper warp thread group is moved downwards. When the warp threads pass through the XY plane, the weft thread is fixed by the warp threads and a new shed is opened. The next weft thread is introduced into this shed. The woven fabric is produced step by step by repeating this process. The length of the woven fabric in the Y direction is limited only by the maximum possible length of the warp threads and is typically 100 m. The width of the woven fabric is limited by the width of the loom and the devices thereof and is typically 1-2 m. The woven fabric produced according to the above-described process is characterised in that a weft thread passes over precisely one and then under precisely one warp thread. The same applies vice versa for the warp threads in relation to the weft threads. This type of woven fabric formation is referred to as “plain weave” or “1:1 weave”. Other weave types, for example twill weave or satin weave, are also made possible by grouping the warp threads differently or increasing the number of warp thread groups by introducing further heald frames. The greatest possible flexibility in 2D weaving is achieved when each individual warp thread or the heald through which it is passed can be controlled individually. Looms equipped in this manner are called Jacquard machines and allow very complex weaves which can also be changed for each new weft thread.

What is known as “2.5D weaving” is a modification of 2D weaving using a Jacquard machine. In this case, woven two-dimensional formations are produced which can be reshaped into a three-dimensional formation once the weaving is complete. The ability of Jacquard machines to control individual healds individually is used for this purpose. In contrast to 2D weaving, where only precisely one shed is formed, in 2.5D weaving a plurality of sheds is produced one on top of another, into each of which a separate weft thread is introduced. In this way, two or more woven parts are in practice produced in parallel, one on top of another and separately from each other for the time being, on a loom. By controlling the healds in a suitable manner, it is possible to connect the upper and lower woven parts which thus far have been separate. Let us assume that four warp thread groups have been formed in a correspondingly equipped loom (Jacquard machine): two upper warp thread groups which form the upper sheds, and two lower warp thread groups which form the lower sheds. Once an upper and a lower woven part having a given length in the Y direction (see for exampleFIG. 6B) have been woven by means of the upper and lower sheds, the two upper warp thread groups are guided downwards. The two lower warp thread groups are accordingly guided upwards. This produces a common crossing region of the upper and the lower woven part along the X direction. Weaving is then continued. However, the warp threads which before the crossing point formed the upper woven part now extend in the lower woven part, and the formerly lower warp threads extend in the upper woven part. As 2D weaving is continued, further crossing regions of the two woven parts are produced by the switching of lower and upper warp thread groups. A two-ply woven fabric is produced by interconnecting the layers in the crossing regions. After completion of the weaving process, the multiple layers are severed between the crossing regions in the weft direction (X direction). A cross-shaped arrangement of the woven parts in relation to each other is produced by opening the woven parts which lie one on top of the other (see for exampleFIG. 6A-7F).

In the case of both 2D and 2.5D weaving, weaving takes place in a plane XY and in planes XY1, XY2, etc. which are parallel thereto. This means that the two groups of threads which are involved, warp threads and weft threads, extend in the XY plane, if the undulations in the Z direction as a result of the crossing over of warp and weft are disregarded. This is not the case in 3D weaving.

In contrast to 2D weaving, in 3D weaving fibres can be woven directly in three spatial directions. At the same time there is even greater flexibility with regard to the number and arrangement of warp and weft threads. In typical 3D weaving machines the warp threads extend in the Z direction. The healds through which the warp threads extend can be arranged side by side in a row, as in 2D weaving, or in any desired arrangement, for example in a square or cross shape, depending on what cross-sectional shape of the subsequent 3D woven fabric is desired. There can be one or more weft threads. The weft threads are provided on spools which are in turn mounted on what are known as “bobbins”. The bobbins can be passed around the warp threads and/or other weft threads in a matrix of freely programmable paths in the XY plane, such that even very complex geometries and weaves can be produced. The interwoven weft threads are oriented substantially in the XY plane. The distinguishing feature in relation to 2D and 2.5D weaving is the orientation of the weft threads in the XY plane and of the warp threads in the Z direction during weaving. In 2D weaving the warp threads and weft threads are oriented only in the XY plane. In 2.5D weaving the warp threads and weft threads also extend substantially in the XY plane during weaving and are reoriented into the third spatial direction Z only after weaving, by reshaping or opening the woven structure.

According to a further configuration, the different fibres are interwoven with other fibres in two and a half dimensions. If the first and the second fibre portion are part of different fibres, 2.5D weaving for example can be used. Cost-effective weaving can thus be achieved.

According to a further configuration of the structural arrangement according to the invention, the different fibres are sewn together, interwoven or interlaced by means of fibres and/or the different fibres are adhesively bonded to each other in particular by means of a thermoplastic strand, a thread coated with thermoplastic material, or an adhesive tape. The different fibres can easily be interconnected for example by sewing or adhesive bonding.

According to a further configuration of the structural arrangement according to the invention, the first and/or the second portion of the first fibre portion is integrated, in particular glued, into the first and/or the second portion of the box structure, and/or the inner web is integrated, in particular glued, into the supporting element, the supporting element preferably being designed as a rib, transverse web or spar and/or being connected to the box structure. “Integrated” means in particular that the first and/or the second portion of the first fibre portion extends inside a wall of the box structure, at least in portions. For example, the first or the second portion of the first fibre portion can be integrated into the wall of the box structure in the dry state, whereupon the wall and the first and/or the second portion of the first fibre portion are infiltrated with a matrix. According to an alternative embodiment, the first and/or the second portion of the first fibre portion and the wall of the box structure can each be provided as a prepreg material, whereupon the first and/or the second portion of the first fibre portion is integrated into the wet wall in the wet state. According to another alternative embodiment, the first and/or the second portion of the first fibre portion is integrated into the wall of the box structure, which wall is as yet uncured or cured only in part, in the cured state (in this connection, “cured” relates to a corresponding matrix between the respective fibre portions). As another alternative, the first and/or the second portion of the first fibre portion is integrated into the cured wall of the box structure in the uncured or only partially cured state. By means of the above-described measures it is possible to achieve a good connection between the first and/or the second portion of the first fibre portion and the wall of the box structure. The above comments apply accordingly for the inner web and the integration thereof into corresponding ribs, transverse webs or spars. The one or more ribs (or spars) form part of the structural arrangement and can absorb loads from the inner web or introduce loads into said web. In the present case, “ribs” and “spars” refer to structural elements which increase dimensional stability. Ribs support in particular the aerodynamic profile of lift-generating surfaces (for example wings, control surfaces, tail unit fins) and preferably extend parallel to the flight or oncoming flow direction. In contrast thereto, spars preferably extend substantially in the span direction and their main function is to introduce bending loads from the lift-generating surface to force-introduction ribs (rib having a force introduction point) or directly into force introduction points, for example into the attachment point in the present case (which is designed for example as an eye). Ribs and spars preferably structurally interconnect the upper and the lower shell of the lift-generating surfaces.

According to a further configuration of the structural arrangement according to the invention, the first and/or the second portion, the inner and/or the outer web tapers in a direction away from the crossing point. As a result, the connection formed by the first and/or the second portion and the wall of the box structure or the connection between the inner and/or the outer web and corresponding ribs or spars has an even higher loading capacity.

According to a further configuration of the structural arrangement according to the invention, the attachment point is designed as an eye, metal fitting, rivet field, bonded joint and/or weld. An attachment point of this type is easy to produce and offers versatile connection options.

According to a further configuration of the structural arrangement according to the invention, the eye is designed for mounting a control member, in particular a flap carriage, a lever and/or a coupling rod. In this case, the eye preferably extends transversely through the outer web.

According to a further configuration of the structural arrangement according to the invention, the first and the second plane are substantially perpendicular to each other. “Substantially” means an angular range between the first and the second plane of between 45 and 135°, preferably 80 and 100°, more preferably 85 and 95°.

According to a further configuration of the structural arrangement according to the invention, the first and/or the second fibre portion is embedded in a matrix. The matrix can be an epoxy (resin) matrix or thermoplastic matrix.

According to a further configuration of the vehicle according to the invention, a control flap comprises the structural arrangement. In the present case, “control flap” means in particular a flap, a control surface or a spoiler. “Control flap” preferably means an actively moved control flap. However, it may also be a control flap which is moved passively (without supplying external electric, hydraulic or pneumatic energy). An aerofoil or control surface, for example a rudder unit or a horizontal tail plane, can also comprise the structural arrangement. Passenger doors, freight loading gates and connections for floors or struts can also comprise the structural arrangement.

According to a further configuration of the vehicle according to the invention, an adjusting member arranged at an aerofoil or control surface acts on the eye of the structural arrangement. In relation to the vehicle, aerofoil or control surface means a stationary or substantially stationary aerofoil or control surface (for example a trimmable horizontal tail plane). In particular, “aerofoil or control surface” means the stationary part of a wing, horizontal tail plane or rudder unit of an aircraft.

According to a further configuration of the vehicle according to the invention, the adjusting member is designed as a flap carriage which on one hand is displaceably arranged at the aerofoil and on the other hand is in engagement with the eye of the structural arrangement. The second fibre portion of the structural arrangement transfers the forces introduced into the eye from the adjusting member, in particular the flap carriage, to the inner web and the two portions of the structural arrangement.

In the figures, like reference numerals denote like or functionally like components, unless indicated otherwise.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 2is a partial perspective view of a structural arrangement200according to one embodiment of the present invention which is kept comparatively general.

The structural arrangement200is for example part of the landing flap102shown inFIG. 1and thus part of the aircraft100.

In the present case, the three mutually orthogonal spatial directions are denoted X, Y and Z. This is merely to facilitate better understanding of the spatial arrangement of the various components in relation to each other. In the case of the landing flap102, X denotes the oncoming flow direction, Y denotes the span direction and Z denotes the vertical direction.

The structural arrangement200comprises a substantially closed box structure202which is shown by dashed lines inFIG. 2. “Substantially closed” means that the box structure202has no or only comparatively small openings in its outer walls204. The front outer wall206is transparent inFIG. 2in order for it to be possible to see the interior208of the box structure202.

The structural arrangement200further comprises a fibre construct210which is made up of first and second fibre portions212,214, only a single first fibre portion212of this type and a single second fibre portion214of this type being shown in the YZ plane in order to facilitate better understanding. As many fibre portions212and214of this type as desired can be arranged side by side in the X direction in the structural arrangement200. To facilitate better differentiation, the first and the second fibre portion212,214are distinguished by short dashes in opposite directions. A respective fibre portion212extends for example in a horizontal XY plane, while a respective second fibre portion214extends for example in a vertical XZ plane. According to the embodiment, a respective first fibre portion212and a respective second fibre portion214thus extend perpendicular to each other.

A respective first fibre portion212and a respective second fibre portion214are interconnected at a crossing point216. This can be achieved for example in that the first and second fibre portions212,214are adhesively bonded to each other, are wound around each other or are coupled to each other by means of a further fibre portion at the crossing point216. In particular, the fibre portions212,214can be interwoven (2.5D weaving, seeFIGS. 6A,7D and7F) or sewn together (seeFIG. 10A to 10C) at the crossing point. A further variant provides that the first and second fibre portions212,214are part of the same fibre, as shown inFIG. 5.

Returning now toFIG. 2, this figure shows that a respective first fibre portion212comprises a first and a second portion218,220, the portions218,220being connected to the lower outer wall204of the box structure202, which wall extends in the XY plane. To be more precise, the first portion218of the first fibre portion212is integrated, in particular glued, into a first portion232of the outer wall204, and the second portion220of the first fibre portion212is integrated, in particular glued, into a second portion233of the outer wall204. For this purpose, the portions232,233of the outer wall204are each fork-shaped. However, it is also conceivable for the portions218,220to be fixed to or in the outer wall204of the box structure202in another manner.

A respective second portion214forms an inner web222, which projects upwards into the interior208of the box structure202, and an outer web224, which extends downwards outside the box structure202. The inner web222is connected to a supporting element234of the structural arrangement200. The supporting element234is designed for example as a rib which is connected to the box structure202. The supporting element234can also be designed as a spar or transverse web, for example. The inner web222is preferably integrated, in particular glued, into the supporting element234.

The outer web224comprises an attachment point226for introduction of a first load230into the outer web224. The attachment point226is designed in particular as an eye, but can also be designed as another structural load transfer member, for example a riveted joint or bonded joint. A corresponding axis of the eye226is denoted by reference numeral228.

The second fibre portion214guides the first load230introduced at the attachment point226from the attachment point226into the supporting element234. The first fibre portion212simultaneously transfers a second load235between the first and the second portion232,233of the box structure202. Thus, two substantially mutually independent load paths are provided. For example, bending loads235in the outer wall204are guided through the crossing point216by means of the first fibre portions212, while—substantially unaffected thereby—the retaining forces230introduced at the eye226by means of the flap carriages106,108are guided into the supporting element234. Peeling of the eye226is effectively prevented in spite of the fibre composite construction.

The portions218,220can be glued into the outer wall204of the box structure202in various ways. The completely or partially cured portions218,220can be cured together with the wet outer wall204. In addition, the completely or partially cured portions218,220can be structurally adhesively bonded to the completely or partially cured outer wall204. In addition, the dry portions218,220can be infiltrated and cured together with the dry outer wall204. The wet portions218,220(prepreg) can also be adhesively bonded to the wet outer wall204.

In addition, the inner web222is preferably also glued into the rib234(or a spar or transverse web) in one of the ways described above for the portions218,220. However, it is again also conceivable for the inner web222to be attached to the rib234in another way, for example by bolting or screwing.

In one embodiment, the fibre construct210is provided with a resin matrix which is cured before or after integration of the fibre construct210into the box structure202. In particular, joint impregnation of the box structure202(which in this case is likewise designed as a fibre composite material) and of the fibre construct210with the resin matrix in one process step is conceivable.

In addition, the fibre construct210can be produced in one piece with the box structure202, in particular by means of 2.5D or 3D weaving.

FIG. 3Ais a perspective view of the fibre construct210fromFIG. 2in one possible configuration which can be achieved dry, that is to say without matrix, wet, that is to say preimpregnated with matrix, or even in the cured state. The individual fibres cannot be seen owing to the simplified representation.

FIG. 3Ashows the cross-shaped cross-section, already shown inFIG. 2, of the fibre construct210.FIG. 3Aalso shows that the first portion218, the second portion220and the inner web222can taper away from the crossing point216. In contrast, according to the embodiment the outer web224has a constant thickness300.FIG. 3Aalso shows the attachment point formed as an eye226.

The first portion218, the second portion220and the inner web222preferably each taper in steps. A step of this type is denoted by reference numeral302by way of example. The steplike construction is produced in that the first and second fibre portions212,214are trimmed in steps or woven accordingly (seeFIG. 5).

FIG. 3Bis a sectional view of the integration of the fibre construct210fromFIG. 3Ainto the box structure202. The portions218,220each extend into the fork-shaped portions232,233of the outer wall204. To be more precise, the portions218,220extend between a plurality of fibre layers304which form the outer wall204and the fork-shaped portions232,233. The inner web222extends into the inner rib234, which also extends in a fork-shaped manner for this purpose and comprises fibre layers304. The outer web224extends into an outer rib308which comprises fibre layers304and according to the embodiment ends with the web224.

According to the embodiment, the fibre layers304form the outer wall204, the fork-shaped portions232,233and the ribs234,308. For this purpose the fibre layers304are arranged in the form of angles on the fibre construct210.

A resin matrix306is shown by dots in only one region by way of example. The resin matrix306fills all the free spaces between the fibre construct210and the layers304as well as intermediate spaces between the layers304.

As can be seen fromFIG. 3B, the outer web224, viewed in cross-section, is designed to be longer than the portions218,220and the inner web222, which are preferably designed to be approximately equal in length. As a result, the eye226can be spaced comparatively far apart from the portions218,220and thus from the outer wall204of the box structure202.

FIGS. 4A and 4Bshow the views fromFIGS. 3A and 3B, with the difference that in the embodiment according toFIGS. 4A and 4Bthe outer web224has the same length as the portions218,220and the inner web222. In addition, the outer web224tapers in a direction away from the crossing point, in the same way as the portions218,220and the inner web222. The outer rib308widens out in a fork-shaped manner in order to accommodate the outer web224. In addition, the fibre layers304are trimmed in steps. A step of this type is denoted by reference numeral400. As a result, a connection having a particularly high loading capacity of the fibre layers304to the fibre construct210can be achieved.

FIG. 5, which was discussed at the outset, shows an exemplary section in the region of the crossing point216fromFIG. 2.

FIG. 5shows how it is possible for respective first and second fibre portions212,214to be formed as part of a single fibre500. For this purpose, the fibres500are three-dimensionally interwoven with fibres502.

By means of 3D weaving it is thus easy to produce a fibre construct210in which a respective fibre500forms the portions218,220and the webs222,224.

After completion of the weaving process, the fibre construct210is infiltrated by a resin matrix306which fills all the intermediate spaces between the fibres500,502.

In contrast toFIG. 5,FIG. 6Ashows a fibre construct210which has been produced by means of 2.5D weaving. In this case, the first and the second fibre portion212,214are formed of different fibres600,602, which form what are known as warp threads and are interwoven in two and a half dimensions with fibres502which form what are known as weft threads. The fibres600and602each wind around the same fibres502at the crossing point216, whereby the fibres600and602and thus the first and second fibre portions212,214are interconnected.

FIG. 6Bshows how the fibres502,600,602, located substantially in one plane, are interwoven. For this purpose, the fibres600,602(warp threads) are each moved in the vertical direction Z (see arrows) by means of a heald604of a Jacquard machine, in order thereby to form an upper shed606and a lower shed608through which the fibres502(weft threads) are moved.

After completion of the woven fabric, the fibres602, together with the fibres502respectively allocated thereto, are pivoted upwards or downwards (that is to say, reshaped), as indicated by corresponding arrows inFIG. 6A, in order to form the fibre construct210.

FIG. 7Ashows a fibre construct210which is also produced by means of 2.5D weaving and in contrast toFIG. 6Ahas already been integrated into the box structure202, as described above for example with reference toFIG. 3B.

In addition, in the case of the fibre construct210according toFIG. 7A, the portions218,220and the webs222,224are each preferably U-shaped, comprising two arms700. Layers304are arranged on, under and in an intermediate space702between the arms600. The arms600can each taper away from the crossing point216, for example until they reach a thickness which corresponds to the thickness of a respective layer304.

The intermediate space702can obviously also be infiltrated by the matrix306.

FIGS. 7B and 7Cshow schematically two states during production of the fibre construct210fromFIG. 7A.

FIG. 7Bshows how all the arms700are woven substantially in one plane. After this, the two upper and two lower arms700are bent upwards and downwards respectively such that, as shown inFIG. 7C, the webs222,224and the portions218,220are formed.

FIG. 7Dshows in detail the fibre orientations fromFIG. 7Baccording to one embodiment. In the embodiment according toFIG. 7D, the fibres602are each woven in such a way that they extend in the diagonally opposing arms700. In the region of the crossing point216, the fibres602accordingly extend obliquely in the YZ plane and in particular between two fibres502.

FIG. 7Eshows in detail the fibre orientations fromFIG. 7Caccording to one embodiment.

FIG. 7Fshows a variation on the embodiment according toFIG. 7D, which variation comprises a different fibre orientation. In the embodiment according toFIG. 7F, the fibres602are each woven in such a way that they extend in the directly opposing arms700, that is to say in arms700which are located in the same XY plane. In the region of the crossing point216, the fibres602accordingly extend in a U-shape in the YZ plane and in particular between two fibres502. A respective fibre602preferably winds around a fibre502at the point denoted by reference numeral704.

In particular with reference to the fibre orientation shown inFIG. 6A to 7F, it is clear that—after the reshaping step to form the respective fibre construct210—the fibres602guide the first load230substantially in the XY plane through the crossing point216, while the fibres600guide the second load235in the XY plane through the crossing point216. The first and the second load230,235have basically no effect on each other.

The weaving methods shown inFIG. 6A to 7Fare referred to herein as weaving methods in two and a half dimensions and have the advantage that a corresponding weaving apparatus needs to have only a small weaving capacity in the Z direction (third dimension).

A further embodiment of a structural arrangement200will be described below with reference toFIG. 8A to 8D.

FIG. 8Ais a perspective view of the structural arrangement200. The structural arrangement200forms part of a landing flap102.

The structural arrangement202comprises a substantially closed box structure202which forms the outer wall204of the aerodynamic profile of the landing flap102. The box structure202ofFIG. 8Ais preferably designed to be open in the Y direction, that is to say the span direction. Ribs234and transverse webs800extend inside the box structure202.

A fibre construct210, as described for example with reference toFIG. 2, is integrated into the box structure in such a way that the outer web224of said fibre construct extends downwards in the Z direction. The inner web222of the fibre construct210points into an interior208of the box structure202and is preferably integrated into the rib234. The first and second portions218,220of the fibre construct210are integrated into the lower outer wall802. The eye226is thus arranged below the box structure202and is thus suitable to be connected to a flap carriage106(not shown).

As is clear from the sectional view along the line I-I fromFIG. 8A, which is shown inFIG. 8Band shows a more specific configuration than that ofFIG. 8A, the web222is located inside the rib234, which is preferably connected at the entire periphery thereof to the outer skin204. The left- and right-hand end of the web222inFIG. 8Bis indicated by a dot-dash line. The web222could also be formed in one piece, in particular 3D woven, with the rib234.

In particular,FIG. 8Bshows that the rib234and preferably the inner web222adjoin the upper outer wall804of the box structure202at the top, that is to say are attached thereto.

The outer web224and the optionally provided outer rib308may comprise bevels806in order also to save material.

FIG. 8Dis a sectional view along the line fromFIG. 8B. To facilitate representation,FIG. 8Ddoes not differentiate between the material of the fibre construct210and the material of the box structure202.

FIG. 8Dshows that the structural arrangement200can also comprise a pair of angles808, for example made of fibre composite material or metal, which are arranged on either side of the outer web224(or optionally of the outer rib308) and reinforce the eye226. The angles808each comprise webs810including eyes812which correspond to the eye226in the fibre construct210. The angles808each also comprise a foot814by which they rest against the lower outer wall802. The feet814are typically each attached to the box structure202by four bolts816. The bolts816may comprise a head818by which they engage behind the upper outer wall804and the shank820of said bolts can extend through the fibre construct210. The end822of a respective shank820is screwed to the corresponding foot814.

As shown inFIG. 8C, which is a view from below in direction II fromFIG. 8A, eight bolts816per fibre construct210can be provided, which penetrate said fibre construct or are arranged adjacent thereto. To provide a better overview, the angles808and the web224are not shown in the view ofFIG. 8C.

According to another alternative configuration, the box structure202, the fibre construct210and optionally also the transverse webs800could be produced in one piece by 3D weaving.

FIG. 9shows part of a landing flap102in multi-spar construction, which comprises a structural arrangement200which can be designed according to the model ofFIG. 8A to 8D.

Tubes902made of fibre composite material, in particular CFRP, are inserted in the span direction into intermediate spaces900formed by the box structure202and the transverse webs800. In contrast to the embodiment according toFIG. 8A to 8D, in the embodiment according toFIG. 9a separate skin904is provided which externally surrounds the box structure200and the tubes902after assembly thereof (indicated by the arrows inFIG. 9). The skin904comprises an opening906through which the outer web224comprising the eye226(optionally also including the angles808) is slid. The eye226is obviously accessible from the underside after assembly.

According to one embodiment, the structural arrangement200, the tubes902and the skin904are preformed from dry woven fabric and after assembly the entire construction is infiltrated with a resin matrix and cured.

According to another embodiment, the structural arrangement200, the tubes902and the skin904can be partially cured and after assembly the entire construction is infiltrated with a resin matrix and cured.

According to a further embodiment, the structural arrangement200, the tubes902and the skin904can be cured and the entire construction is adhesively bonded.

FIG. 10A to 10Cshow a plurality of states during production of first and second fibre portions fromFIG. 2in a sewing method according to a further embodiment of the present invention.

First and second fibre portions212,214are laid on a conveyor belt1002which is moved in the conveying direction1000, seeFIG. 10A. The fibre portions212,214are preferably each of the same length and extend in the direction1004transverse to the conveying direction1000. The fibre portions212,214each have an offset1006from one another in the transverse direction1004in the state inFIG. 10A. Edge regions1008,1010are produced as a result, one edge region1008comprising only ends of the second fibre portions214and the other edge region1010comprising only ends of the first fibre portions212.

FIG. 10Bshows how the ends of the second fibre portions214are sewn together in the end region1008. The ends of the first fibre portions212are also sewn together in the other edge region1010. Corresponding needles and sewing fibres are denoted by reference numerals1012and1014.

The first and second fibre portions212,214are also sewn together along a centre line arranged centrally in relation to a total extension1016of the fibre portions212,214in the transverse direction1004. A corresponding needle and sewing fibre are denoted by reference numerals1018and1020. The movement of the needles1012,1018is indicated by a double-headed arrow in each case.

After this, the second fibre portions214are rotated about the centre line, that is to say about the sewing fibre1020, in relation to the first fibre portions212, as indicated by the arrows inFIG. 10C. A fibre construct210is thus formed which hereafter is integrated into a box structure200, seeFIG. 2.

In the case of the fibre construct210, the first and second fibre portions212,214are obviously formed of different fibres600,602.

Instead of a sewing method, the different fibres600,602can be interwoven or interlaced by means of fibres1014,1020. As a further alternative, the different fibres600,602can be adhesively bonded to each other in particular by means of a thermoplastic strand, a thread coated with thermoplastic material, or an adhesive tape.

FIG. 11Ashows a further variation on the embodiment according toFIG. 3A, the portions218,220and the web222of the fibre construct212each having a constant thickness300, that is to say not tapering. An additional web1100is also provided which extends perpendicular to the web222and the portions218,220and is connected to each of these. The web1100can be integrated for example into a transverse web800, seeFIGS. 8A and 8B, and be connected thereto or form said web. The web1100is located in the YZ plane.

The fibre construct212is preferably produced as one piece by means of 3D weaving.

Although the present invention has been described by way of preferred embodiments, it is not in any way limited thereto, but can be modified in various ways. In particular, the embodiments and configurations described for the structural arrangement can be applied accordingly to the vehicle according to the invention and the method according to the invention, and vice versa. Furthermore, “a” or “one” does not exclude a plurality in the present case. In particular, the structural arrangement according to the invention can be applied not only in landing flaps but in all box structures, for example control flaps.