Patent Description:
A modern aircraft such as an airplane includes a communication system. This communication system may include an antenna for relaying signals between the airplane and another remote entity; e.g., another airplane, ground control, satellites, etc. This antenna may be mounted on an exterior of the airplane or within an interior of the airplane; e.g., beneath a skin of an airplane fuselage or an airplane wing. While mounting the antenna on the exterior of the airplane may provide a substantially unobstructed signal path between the exposed antenna and the remote entity, exposure of the antenna increases airplane drag. While mounting the antenna within the interior of the airplane reduces airplane drag, a structure (e.g., skin, frame, etc.) surrounding the antenna may interfere with the signal path between the enclosed antenna and the remote entity.

As a compromise between mounting the antenna within the interior of the airplane and having the antenna exposed on the exterior of the airplane, it is known in the art to dispose the antenna within an aerodynamic fin; e.g., an aerodynamic antenna housing. This fin is mounted on the exterior of the airplane and, thus, positions the antenna outside of the airplane skin and the internal frame. However, such a fin may still interfere with signal transmission between the antenna and the remote entity, particularly where the fin is made from metallic materials and/or uses traditional metal fasteners; e.g., bolts, screws, rivets, etc. Known fins may also be difficult and costly to manufacture.

There is a need in the art for improved techniques and/or assemblies for housing an electric device such as an antenna on an exterior of an aircraft.

<CIT> discloses core structures for composite panels of an aircraft. The core structures include a first side, a second side and a connecting region that interconnects an upper portion of the first side with an upper portion of the second side. The first side, the second side and the connecting region define an housing volume configured to contain an aircraft antenna.

<CIT> discloses an integrated antenna system.

<CIT> discloses a broadband aircraft wingtip antenna system.

<CIT> discloses a cover panel for an aircraft wing.

<CIT> discloses an antenna assembly, a vertical tail, a horizontal tail, a wing, and an aircraft.

According to an aspect of the present invention, an airfoil system is provided in accordance with claim <NUM>.

According to another aspect of the present invention, a manufacturing method is provided in accordance with claim <NUM>.

The following optional features may be applied to the above aspects, insofar as they fall within the scope of the appended claims.

The first airfoil segment and the second airfoil segment may each be configured from or otherwise include non-metallic material.

The method may also include attaching a shield to the airfoil body to form a leading edge of an airfoil. The airfoil may include the airfoil body and the shield.

The first composite material and/or the second composite material may each be or otherwise include fiberglass reinforcement within a resin matrix.

The airfoil system may also include an airfoil which includes a first exterior surface, a second exterior surface and the airfoil body. The airfoil may extend widthwise between the first exterior surface and the second exterior surface. The first airfoil segment may form the first exterior surface. The second airfoil segment may form the second exterior surface.

The electric device may be configured as or otherwise include an antenna.

The electric device may be configured as or otherwise include a sensor.

The internal cavity may extend widthwise within the airfoil between a first cavity side and a second cavity side. The first airfoil segment may form the first cavity side. The second airfoil segment may form the second cavity side.

The internal cavity may extend lengthwise within the airfoil between a cavity leading end and a cavity trailing end. The first airfoil segment may form a first portion of the cavity leading end and a first portion of the cavity trailing end. The second airfoil segment may form a second portion of the cavity leading end and a second portion of the cavity trailing end.

The internal cavity may extend spanwise within the airfoil between a cavity base end and a cavity tip end. The first airfoil segment may form a first portion of the cavity base end and a first portion of the cavity tip end. The second airfoil segment may form a second portion of the cavity base end and a second portion of the cavity tip end.

The first airfoil segment may be configured as or otherwise include a first exterior skin that forms the first exterior surface. The second airfoil segment may be configured as or otherwise include a second exterior skin that forms the second exterior surface. The first exterior skin and/or the second exterior skin each be configured from or otherwise include composite material.

The first airfoil segment may include a first exterior skin and a first internal support formed integral with the first exterior skin. The first exterior skin may form the first exterior surface. The second airfoil segment may include a second exterior skin and a second internal support formed integral with the second exterior skin. The second exterior skin may form the second exterior surface. The first internal support may engage and may be attached to the second internal support.

The first internal support may be abutted against and bonded to the second internal support.

The first internal support may include a receptacle. The second internal support may include a key that is mated with the receptacle.

The airfoil may be configured as or otherwise include an airfoil body. The first airfoil segment may be a first half of the airfoil body. The second airfoil segment may be a second half of the airfoil body.

The airfoil may also include a shield. The shield may be configured at and extend spanwise along a leading edge of the airfoil. The shield may overlap and may be attached to a first leading edge portion of the first airfoil segment and a second leading edge portion of the second airfoil segment.

<FIG> illustrates a portion of an assembly <NUM> for an aircraft. Herein, the term "aircraft" may generally describe any mobile device which travels through at least air and/or space. The aircraft, for example, may be configured as an airplane, a helicopter, a spacecraft, a drone (e.g., an unmanned aerial vehicle (UAV)) or a projectile such as, but not limited to, a rocket. The present disclosure, however, is not limited to the foregoing exemplary aircraft configurations.

The aircraft assembly <NUM> of <FIG> includes a base <NUM> and an airfoil system <NUM>. The aircraft assembly base <NUM> may be any portion of the aircraft to which the airfoil system <NUM> may be mounted. The aircraft assembly base <NUM>, for example, may be configured as an exterior skin or other exterior structure of: an aircraft fuselage, an aircraft tail assembly, an aircraft wing, an engine pylon or a nacelle housing an aircraft engine. The present disclosure, however, is not limited to the foregoing exemplary aircraft assembly base configurations.

The airfoil system <NUM> of <FIG> is configured to at least partially or completely form an aerodynamic projection (e.g., a control element, a control surface, etc.) on the aircraft assembly base <NUM>. The airfoil system <NUM> of <FIG>, for example, includes a hollow airfoil <NUM>. This airfoil <NUM> may be configured as a wing, a vane, a fin and/or a vortex generator (e.g., a strake). Examples of the wing may include, but are not limited to, a winglet, a stub wing, a main wing, a tail wing and a stabilizer.

The airfoil system <NUM> of <FIG> is also configured as part of an electronic system <NUM> of the aircraft such as, but not limited to, a communication system and/or a sensor system. The airfoil system <NUM> of <FIG>, for example, includes at least one electric device <NUM> configured with (e.g., housed within) the airfoil <NUM>. This electric device <NUM> may be configured as or otherwise include an antenna such as, but not limited to, a VHF antenna. The electric device <NUM> may also or alternatively be configured as or otherwise include a sensor such as, but not limited to, a prognostics and health management (PHM) sensor. The present disclosure, however, is not limited to the foregoing exemplary electric device configurations nor to communication or sensor system electric components.

Various types of electric devices may suffer from signal interference (e.g., signal loss and/or signal path obstruction) when housed within or otherwise surrounded by metal and/or conductive materials. To reduce or eliminate potential for such signal interference for the electric device <NUM> of <FIG>, the airfoil <NUM> is constructed substantially (or only) from non-metallic and/or dielectric material(s). More particularly, at least a significant portion of a hollow body <NUM> of the airfoil <NUM> that forms a housing and/or a shell about the electric device <NUM> may be constructed substantially (or only) from the non-metallic and/or dielectric material(s). In addition, to facilitate placement of the electric device <NUM> within the airfoil system <NUM> during assembly, the airfoil <NUM> may be configured with a segmented (e.g., clamshell-like) construction. However, to further reduce or eliminate potential for signal interference, the airfoil <NUM> may be configured without, for example, any traditional fasteners (e.g., bolts, screws, rivets, etc.) for securing its airfoil segments 34A and 34B (generally referred to as "<NUM>") together. Additional details regarding the construction of the airfoil <NUM> are described below in further detail.

The airfoil system <NUM> of <FIG> includes the airfoil <NUM> and an airfoil mount <NUM> configured to attach / secure the airfoil system <NUM> and its airfoil <NUM> to the aircraft assembly base <NUM>. The airfoil system <NUM> of <FIG> also includes the electric device <NUM> configured (e.g., embedded, encapsulated and/or otherwise disposed) within the airfoil <NUM>. However, in other embodiments, the airfoil system <NUM> may be configured without the electric device <NUM> in order to provide the aerodynamic projection described herein without also being part of the aircraft electronic system <NUM>. The airfoil <NUM>, for example, may be configured to form a hollow aircraft control element without housing any electric devices therewithin.

The airfoil <NUM> of <FIG> is configured with / includes its hollow airfoil body <NUM>. The airfoil <NUM> of <FIG> also includes a leading edge (LE) shield <NUM> configured to protect the airfoil body <NUM> at a leading edge <NUM> of the airfoil <NUM>.

Referring to <FIG>, the airfoil body <NUM> extends spanwise along a centerline <NUM> (e.g., a span line) of the airfoil <NUM> from a base <NUM> (e.g., a root) of the airfoil <NUM> to a tip <NUM> of the airfoil <NUM>. Referring to <FIG>, the airfoil body <NUM> extends lengthwise along a camber line <NUM> of the airfoil <NUM> from a leading edge <NUM> of the airfoil body <NUM> to a trailing edge <NUM> of the airfoil <NUM>, where the airfoil body leading edge <NUM> is arranged at (e.g., on, adjacent or proximate) the airfoil leading edge <NUM>. In the specific embodiment of <FIG>, the airfoil body leading edge <NUM> is slightly recessed inward from the airfoil leading edge <NUM> by a thickness of the shield <NUM>. However, in other embodiments, the airfoil body leading edge <NUM> may be on (e.g., the same as) the airfoil leading edge <NUM> where, for example, the shield <NUM> is omitted or incorporated as part of the airfoil body <NUM>. Referring again to <FIG>, the airfoil body <NUM> extends widthwise (e.g., transverse to the centerline <NUM> and/or the camber line <NUM>) between and to opposing side exterior surfaces 54A and 54B (generally referred to as "<NUM>") of the airfoil body <NUM>; e.g., exterior-most / outer-most surfaces of the airfoil body <NUM>. Each of these airfoil body exterior surfaces <NUM> may be configured as a convex surface as shown in <FIG>. Alternatively, either one of the airfoil body exterior surfaces 54A or 54B may be a concave surface (see <FIG>) or a substantially flat surface (see <FIG>).

Referring to <FIG> and <FIG>, the airfoil body <NUM> includes the plurality of airfoil segments <NUM>; e.g., a complimentary pair of airfoil segments. These airfoil segments <NUM> may be configured as respective halves of the airfoil body <NUM>. The airfoil segment 34A, for example, may form one half (or portion) of the airfoil body <NUM> on one side of the airfoil body <NUM>; e.g., towards the airfoil body exterior surface 54A. The airfoil segment 34B, on the other hand, may form the other remaining half (or portion) of the airfoil body <NUM> on an opposing side of the airfoil body <NUM>; e.g., towards the airfoil body exterior surface 54B. The airfoil segments <NUM> of <FIG> have substantially identical (but, mirror image) configurations. The present disclosure, however, is not limited to such an exemplary identical, mirror image configuration. For example, referring to <FIG>, the airfoil segments <NUM> may alternatively have different (but, still complementary) configurations.

Referring to <FIG>, each airfoil segment <NUM> extends spanwise along the centerline <NUM> from (or about) the airfoil base <NUM> to the airfoil tip <NUM>. Each airfoil segment <NUM> extends lengthwise along the camber line <NUM> from the airfoil body leading edge <NUM> (or, alternatively the airfoil leading edge <NUM>) to the airfoil trailing edge <NUM>. Each airfoil segment <NUM> extends widthwise from an interior side <NUM> (e.g., an intersegment mating side) of the respective airfoil segment <NUM> to the airfoil body exterior surface <NUM> that is formed by that respective airfoil segment <NUM>.

Referring to <FIG> and <FIG>, each airfoil segment <NUM> includes an exterior skin <NUM> and one or more (e.g., discrete or interconnected) internal supports <NUM>-<NUM>. One or each of the airfoil segments <NUM> may also include an electric device mount <NUM>.

Referring to <FIG>, the exterior skin <NUM> is configured to at least partially or completely form an exterior periphery of the respective airfoil segment <NUM>. For example, the exterior skin <NUM> of <FIG> (e.g., completely) forms its respective airfoil body exterior surface <NUM>. The exterior skin <NUM> of <FIG> also (e.g., partially) forms the airfoil body leading edge <NUM>, the airfoil trailing edge <NUM> and/or the airfoil tip <NUM>. More particularly, the exterior skin <NUM> of <FIG> extends spanwise from (or about) the airfoil base <NUM> to (or about) the airfoil tip <NUM>, and lengthwise from (or about) the airfoil body leading edge <NUM> to (or about) the airfoil trailing edge <NUM>. A leading edge end of the exterior skin <NUM> may thereby at least partially form the airfoil body leading edge <NUM>. A trailing edge end of the exterior skin <NUM> may at least partially for the airfoil trailing edge <NUM>. The exterior skin <NUM> of <FIG> also extends widthwise across the airfoil tip <NUM> to the airfoil segment interior side <NUM>, and lengthwise across the airfoil tip <NUM> between and to the edges <NUM> and <NUM>. The exterior skin <NUM> may thereby form a portion of the airfoil tip <NUM> that is carried by the respective airfoil segment <NUM>.

Referring to <FIG> and <FIG>, each of the internal supports <NUM>-<NUM> may be configured as an internal stiffener (e.g., a structural rib or other member) for supporting and providing rigidity to the respective exterior skin <NUM>. Each of the internal supports <NUM>-<NUM>, for example, is arranged on the airfoil segment interior side <NUM> and is connected to (e.g., formed integral with) the respective exterior skin <NUM>.

Referring to <FIG>, the leading edge (LE) support <NUM> is arranged at (e.g., on, adjacent or proximate) the airfoil body leading edge <NUM>. This LE support <NUM> extends spanwise between and to (or about) the airfoil base <NUM> and the airfoil tip <NUM>. The trailing edge (TE) support <NUM> is arranged at (e.g., on, adjacent or proximate) the airfoil trailing edge <NUM>. This TE support <NUM> extends spanwise between and to (or about) the airfoil base <NUM> and the airfoil tip <NUM>. The intermediate support <NUM> is arranged intermediately (e.g., about midway) spanwise along the centerline <NUM> between the airfoil base <NUM> and the airfoil tip <NUM>. This intermediate support <NUM> extends lengthwise between and to (or about) the LE support <NUM> and the TE support <NUM>.

Referring to <FIG>, each of the internal supports <NUM>-<NUM> may have a channeled and/or tubular configuration; e.g., a hat or top-hat configuration. Each internal support <NUM>, <NUM>, <NUM>, for example, may be configured as a flanged (e.g., outward lipped, or inward lipped) U-channel, C-channel or V-channel beam. More particularly, each internal support <NUM>, <NUM>, <NUM> may have a flanged U-shaped, C-shaped or V-shaped cross-sectional geometry when viewed, for example, in a plane perpendicular to a longitudinal centerline of the internal support; e.g., the plane of <FIG>. The present disclosure, of course, is not limited to the foregoing exemplary internal support configurations.

Each internal support <NUM>, <NUM>, <NUM> may include one or more internal sidewalls <NUM> and <NUM> (e.g., structural flanges) and an internal endwall <NUM> (e.g., a structural web). These support elements <NUM>, <NUM> and <NUM> are configured together to collectively provide the respective internal support <NUM>, <NUM>, <NUM> with an internal support channel <NUM>. This channel <NUM> extends longitudinally along the longitudinal centerline of the respective internal support, where the channel <NUM> of <FIG> is closed off by an interior peripheral portion of the exterior skin <NUM> of the respective airfoil segment <NUM>. Each internal support <NUM>, <NUM>, <NUM> may also include one or more outward lips <NUM> and <NUM> (or inward lips) for fixing the internal support <NUM>, <NUM>, <NUM> to the exterior skin <NUM>.

The internal support members <NUM>, <NUM>, <NUM>, <NUM> and <NUM> of <FIG> are integrally connected together, and each internal support <NUM>, <NUM>, <NUM> is integrally connected to the respective exterior skin <NUM> as described below in further detail. Each of the internal support members <NUM>, <NUM>, <NUM>, <NUM> and <NUM> may extend longitudinally along a portion or an entire longitudinal length of the respective internal support <NUM>, <NUM>, <NUM>.

The first sidewall <NUM> is connected to the respective exterior skin <NUM> at an interior of the respective airfoil segment <NUM> via, for example, the first lip <NUM>. In particular, the first lip <NUM> is connected to and projects out (e.g., in a first direction away from the channel <NUM>) from the first sidewall <NUM>. The first lip <NUM> of <FIG> extends along and is connected to the respective exterior skin <NUM>. The first sidewall <NUM> projects inward from the respective exterior skin <NUM> and the first lip <NUM> to a distal end <NUM> of the respective internal support <NUM>, <NUM>, <NUM>.

The second sidewall <NUM> is connected to the respective exterior skin <NUM> at the interior of the respective airfoil segment <NUM> via, for example, the second lip <NUM>. In particular, the second lip <NUM> is connected to and projects out (e.g., in a second direction away from the channel <NUM> that is opposite the first direction) from the second sidewall <NUM>. The second lip <NUM> of <FIG> extends along and is connected to the respective exterior skin <NUM>. The second sidewall <NUM> projects inward from the respective exterior skin <NUM> and the second lip <NUM> to the distal end <NUM> of the respective internal support <NUM>, <NUM>, <NUM>.

The endwall <NUM> is arranged at (e.g., on, adjacent or proximate) the distal end <NUM> of the respective internal support <NUM>, <NUM>, <NUM>. The endwall <NUM> of <FIG> is connected to and extends between the first sidewall <NUM> and the second sidewall <NUM>. With this arrangement, the internal support channel <NUM> extends between and to the respective exterior skin <NUM> and the endwall <NUM>. The internal support channel <NUM> also extends between and to the opposing sidewalls <NUM> and <NUM>.

Each internal support <NUM>, <NUM>, <NUM> may also include a segment-to-segment mount <NUM> (e.g., an inter-lockable coupler, an interface, etc.), which is shown schematically in <FIG>. Referring to <FIG>, each segment mount <NUM> may extend longitudinally along the respective internal support <NUM>, <NUM>, <NUM>. A longitudinal length <NUM> of the segment mount <NUM> may be equal to or less than a longitudinal length <NUM> of the respective internal support <NUM>, <NUM>, <NUM>. For example, the segment mount length <NUM> may be greater than fifty percent (<NUM>%), sixty percent (<NUM>%), seventy percent (<NUM>%), eighty percent (<NUM>%) or ninety percent (<NUM>%) of the internal support length <NUM>, but equal to or less than the internal support length <NUM>. In some embodiments, the segment mount <NUM> may extend uninterrupted along its entire longitudinal length <NUM>. In other embodiments, the segment mount <NUM> may be longitudinally interrupted; e.g., cut, formed by multiple spaced (or abutted) segments represented by dashed lines <NUM> in <FIG>, etc..

Referring to <FIG>, the segment mount <NUM> is connected to (e.g., formed integral with) the respective endwall <NUM>. A base <NUM> of the segment mount <NUM>, for example, may be embedded within (or otherwise configured with and/or coupled to) material of the respective endwall <NUM>. A first portion <NUM> of the endwall material in <FIG>, for example, overlaps a first side <NUM> of the segment mount base <NUM>. The base first side <NUM> is thereby captured (e.g., sandwiched) between and secured (e.g., bonded) to the first portion <NUM> of the endwall material and a base portion <NUM> of the endwall material. In addition, a second portion <NUM> of the endwall material in <FIG> overlaps a second side <NUM> of the segment mount base <NUM>. The base second side <NUM> is thereby captured (e.g., sandwiched) between and secured (e.g., bonded) to the second portion <NUM> of the endwall material and the base portion <NUM> of the endwall material.

An interface <NUM> of the segment mount <NUM> is connected to (e.g., formed integral with) and projects out from the segment mount base <NUM> to a distal end of the segment mount interface <NUM> / the segment mount <NUM>. This segment mount interface <NUM> is configured to mate with another one of the segment mount interfaces <NUM> configured with the corresponding internal support <NUM>, <NUM>, <NUM> of the other (e.g., opposing) airfoil segment <NUM>. For example, referring to <FIG>, one of the segment mounts <NUM> may be configured as a receptacle <NUM> with a receptacle aperture <NUM>; e.g., a channel, a slot, a groove, etc. The other one of the segment mounts <NUM> may be configured as a key <NUM> with a key protrusion <NUM>; e.g., a rib, a rail, a rim, etc. With such an arrangement, when the key <NUM> mates with the receptacle <NUM>, the key protrusion <NUM> may project into the receptacle aperture <NUM> to provide an inter-locking (e.g., tongue-and-groove) interface between the respective segment mounts <NUM>. The key <NUM> and its protrusion <NUM> may also be attached (e.g., bonded) to the receptacle <NUM> to fixedly secure the engaged (e.g., interlocked) segment mounts <NUM> together.

Referring again to <FIG> and <FIG>, the electric device mount <NUM> is arranged at the interior of the respective airfoil segment <NUM>. The electric device mount <NUM> of <FIG> and <FIG>, for example, is arranged lengthwise between the LE support <NUM> and the TE support <NUM>. This electric device mount <NUM> is also arranged spanwise between the intermediate support <NUM> and the airfoil tip <NUM>. Referring to <FIG>, the electric device mount <NUM> may be spaced from the respective exterior skin <NUM> by a (e.g., air) gap <NUM>.

The electric device mount <NUM> may be connected to (e.g., formed integral with) one or more or each of the internal supports <NUM>-<NUM> of the respective airfoil segment <NUM>. The electric device mount <NUM>, for example, may extend lengthwise between and to the LE support <NUM> and the TE support <NUM>. As best seen in <FIG>, the electric device mount <NUM> may also or alternatively project out from the intermediate support <NUM> towards the airfoil tip <NUM>.

The electric device mount <NUM> may be configured as an internal mounting tray. The electric device mount <NUM> of <FIG> and <FIG>, for example, has a generally plate-like configuration.

Referring to <FIG> and <FIG>, the airfoil body <NUM> is formed by attaching the airfoil segments <NUM> together. The edges of the exterior skins <NUM> are aligned, for example, and may be attached (e.g., bonded) together using bonding material such as resin or any other adhesive, and/or joined via a sealant material. Internal support structures (e.g., networks of the internal supports <NUM>-<NUM>) of the airfoil segments <NUM> are also aligned and may be attached (e.g., bonded) together using bonding material such as resin or any other adhesive. For example, the LE support <NUM> of one of the airfoil segments 34A is aligned with the LE support <NUM> of the other one of the airfoil segments 34B. The segment mounts <NUM> of those LE supports <NUM> are mated and/or secured together as described above; e.g., see <FIG>. The TE support <NUM> of one of the airfoil segments 34A is aligned with the TE support <NUM> of the other one of the airfoil segments 34B. The segment mounts <NUM> of those TE supports <NUM> are mated and/or secured together as described above; e.g., see <FIG>. The intermediate support <NUM> of one of the airfoil segments 34A is aligned with the intermediate support <NUM> of the other one of the airfoil segments 34B. The segment mounts <NUM> of those intermediate supports <NUM> are mated and/or secured together as described above; e.g., see <FIG>. With such an arrangement, the airfoil segments <NUM> may be connected together without, for example, use of any traditional (e.g., metal and/or otherwise) fasteners; e.g., bolts, screws, rivets, etc. The airfoil body <NUM> may therefore be a fastener-free body.

The airfoil body <NUM> is configured with one or more internal cavities <NUM>-<NUM>. Referring to <FIG>, the leading edge (LE) cavity <NUM> is arranged at the airfoil body leading edge <NUM>. This LE cavity <NUM> is formed collectively by the joined exterior skins <NUM> and the joined LE supports <NUM>. The LE cavity <NUM>, for example, extends lengthwise within the airfoil body <NUM> from the joined exterior skins <NUM> to the joined LE supports <NUM>. The LE cavity <NUM> extends widthwise within the airfoil body <NUM> between the opposing exterior skins <NUM>. The LE cavity <NUM> extends spanwise within the airfoil body <NUM>, and along the airfoil body leading edge <NUM>, from (or about) the airfoil base <NUM> to the joined exterior skins <NUM> at the airfoil tip <NUM>; see also <FIG>.

The trailing edge (TE) cavity <NUM> is arranged at the airfoil trailing edge <NUM>. This TE cavity <NUM> is formed collectively by the joined exterior skins <NUM> and the joined TE supports <NUM>. The TE cavity <NUM>, for example, extends lengthwise within the airfoil body <NUM> from the joined exterior skins <NUM> to the joined TE supports <NUM>. The TE cavity <NUM> extends widthwise within the airfoil body <NUM> between the opposing exterior skins <NUM>. The TE cavity <NUM> extends spanwise within the airfoil body <NUM>, and along the airfoil trailing edge <NUM>, from (or about) the airfoil base <NUM> to the joined exterior skins <NUM> at the airfoil tip <NUM>; see also <FIG>.

Referring to <FIG> and <FIG>, the inner cavity <NUM> is arranged at the airfoil base <NUM>. This inner cavity <NUM> is formed collectively by the joined exterior skins <NUM>, the joined LE supports <NUM>, the joined TE supports <NUM> and the joined intermediate supports <NUM>. The inner cavity <NUM>, for example, extends lengthwise within the airfoil body <NUM> from the joined LE supports <NUM> to the joined TE supports <NUM>. The inner cavity <NUM> extends widthwise within the airfoil body <NUM> between the opposing exterior skins <NUM>. The inner cavity <NUM> extends spanwise within the airfoil body <NUM> from (or about) the airfoil base <NUM> to the joined intermediate supports <NUM>.

Referring to <FIG> and <FIG>, the outer (e.g., electric device) cavity <NUM> is arranged at the airfoil tip <NUM>. This outer cavity <NUM> is formed collectively by the joined exterior skins <NUM>, the joined LE supports <NUM>, the joined TE supports <NUM>, the joined intermediate supports <NUM> and the electric device mounts <NUM>. The outer cavity <NUM>, for example, extends lengthwise within the airfoil body <NUM> from the joined LE supports <NUM> (e.g., a leading edge (LE) end of the outer cavity <NUM>) to the joined TE supports <NUM> (e.g., a trailing edge (TE) end of the outer cavity <NUM>). The outer cavity <NUM> extends widthwise within the airfoil body <NUM> between the opposing exterior skins <NUM> and/or the opposing electric device mounts <NUM>; e.g., between opposing sides of the outer cavity <NUM>. The outer cavity <NUM> extends spanwise within the airfoil body <NUM> from the joined intermediate supports <NUM> (e.g., a lower, base end of the outer cavity <NUM>) to the joined exterior skins <NUM> at the airfoil tip <NUM> (e.g., an upper, tip end of the outer cavity <NUM>).

The outer cavity <NUM> of <FIG> and <FIG> is configured (e.g., shaped and sized) to at least partially or completely receive the electric device <NUM> therewith. The electric device <NUM> is thereby arranged within the outer cavity <NUM> (prior to assembly and attachment of the airfoil segments <NUM>). The electric device <NUM> is secured within the airfoil body <NUM> by attaching the electric device <NUM> to one or each of the airfoil segments <NUM>. The electric device <NUM> of <FIG> and <FIG>, for example, may be attached (e.g., bonded) to one or each of the opposing electric device mounts <NUM> using bonding material such as resin or any other adhesive.

The shield <NUM> of <FIG> is configured to protect the airfoil body leading edge <NUM> from foreign object damage (FOD), erosion and/or other damage. The shield <NUM>, for example, may be formed from a durable material such as metal; e.g., nickel (Ni). The shield <NUM> is attached to the airfoil body <NUM>. A leading edge portion of the airfoil body <NUM>, for example, is inserted into an internal channel of the shield <NUM> such that an interior surface <NUM> of the shield <NUM> is engaged with (e.g., abutted against) an exterior (e.g., the surfaces <NUM>) of the airfoil body <NUM> at its leading edge <NUM>. The shield <NUM> may be attached (e.g., bonded) to the airfoil body <NUM> and its exterior skins <NUM> using bonding material such as resin or any other adhesive.

Referring to <FIG>, the shield <NUM> may extend along a majority (e.g., at least <NUM>-<NUM>%) or an entirety of the airfoil body leading edge <NUM>. The shield <NUM> of <FIG> may thereby at least partially or completely form the airfoil leading edge <NUM>. The shield <NUM> also forms leading edge portions of opposing exterior surfaces 120A and 120B (generally referred to as "<NUM>") (e.g., exposed side surfaces) of the airfoil <NUM>. The remaining portions (and substantially a majority) of the opposing airfoil exterior surfaces <NUM> are formed by exposed portions of the exterior skins <NUM> and their exterior surfaces <NUM>. The exterior skins <NUM> of the airfoil body <NUM> are thereby arranged at and may at least partially form (or completely form where the shield <NUM> is omitted) the opposing airfoil exterior surfaces <NUM>.

Referring still to <FIG>, the airfoil mount <NUM> is arranged at the airfoil base <NUM>. The airfoil mount <NUM> is connected to (e.g., formed integral with) the airfoil body <NUM>. The airfoil mount <NUM> of <FIG>, for example, includes one or more flanges 122A and 122B (generally referred to as "<NUM>"); see also <FIG>. Each of these flanges <NUM> is connected to and projects outward from a respective one of the exterior skins <NUM>. The airfoil mount <NUM> and its flanges <NUM> are connected (e.g., mechanically fastened, bonded and/or otherwise attached) to the aircraft assembly base <NUM> to fixedly secure the airfoil system <NUM> and its airfoil <NUM> to the aircraft assembly base <NUM>. The airfoil mount <NUM>, for example, may be mechanically fastened to the aircraft assembly base <NUM> using one or more fasteners <NUM>, and/or bonded using bonding material such as resin or any other adhesive.

The airfoil body <NUM> and its airfoil segments <NUM> may be constructed substantially (or only) from the non-metallic and/or dielectric material(s). In particular, the airfoil body <NUM> and its airfoil segments <NUM> may be constructed substantially (or only) from composite material such as, but not limited to, non-metallic fiber reinforcement within a matrix. An example of the non-metallic fiber reinforcement is, but is not limited to, fiberglass. An example of the matrix is, but is not limited to, polymer (e.g., thermoplastic or thermoset) resin.

Referring to <FIG> and <FIG>, each airfoil segment <NUM> and its various components <NUM>, <NUM>-<NUM> and <NUM> may be formed together as a single, monolithic body. Herein, the term "monolithic" may described a single, unitary body formed (e.g., resin pressure molded (RPM), resin transfer molded (RTM) or otherwise constructed) as a single collective mass of material. For example, while the segment mounts <NUM> may be constructed from material that is different than the material (e.g., the non-metallic and/or dielectric material(s)) of the remainder their respective airfoil segment <NUM>, each segment mount <NUM> may be laid up integrally with and incorporated with the other material during the formation process. The term "monolithic" may also describe herein a single, unitary body formed from discrete elements that are permanently attached together via, for example, fusion, welding and/or an adhesive (e.g., epoxy resin). A non-monolithic body, by contrast, includes discretely formed bodies which are removably attached together; e.g., mechanically fastened together, brazed together, etc..

As described above, the segment mounts <NUM> may be constructed from material that is different than the remainder their respective airfoil segment <NUM>. Each segment mount <NUM>, for example, may be constructed from metal such as, but not limited to, aluminum (Al). Thus, while the non-metallic and/or dielectric material(s) is selected to reduce signal interference for the electric device <NUM> and/or airfoil reduce weight, the segment mount material may be selected to provide a more robust, rigid, precise connection between the airfoil segments <NUM>. Of course, in other embodiments, one or more of the segment mounts <NUM> may be constructed from composite material (e.g., non-metallic material), which composite material may be the same or different than the material forming the remainder of the respective airfoil segment <NUM>. In still other embodiments, one or more respective pairs of the segment mounts <NUM> may be omitted as shown, for example, in <FIG>. One or more of respective sets of endwalls <NUM>, for example, may be joined directly together via, for example, an adhesive butt connection.

Each airfoil segment <NUM> may be formed using resin pressure molding (RPM), resin transfer molding (RTM) and/or various other molding process. For example, one or more plies of reinforcement material (e.g., fiberglass) may be arranged within a mold. By using one or more mandrels, the reinforcement material may be arranged to form a preform (e.g., a body having a general shape) of the respective airfoil segment <NUM> and each of its members <NUM>, <NUM>-<NUM> and <NUM>. In addition, the respective segment mounts <NUM> may also be laid up with the reinforcement material (e.g., between the plies) such that those mounts <NUM> are formed integral with the airfoil segment <NUM>; e.g., see <FIG> and <FIG>. The mold may then be closed, and resin may be injected into the closed mold under pressure to infiltrate the reinforcement material and form a matrix in which the reinforcements material is embedded. The resin may then be cured under elevated pressure and/or an elevated temperature. Following this curing, the mandrels are removed from the airfoil segment <NUM> and the airfoil segment <NUM> is removed from the mold. Each airfoil segment <NUM> may thereby be integrally formed using a single molding process. This may reduce complexity and/or costs of airfoil manufacture. The present disclosure, however, is not limited to the foregoing exemplary manufacturing techniques.

<FIG> is a flow diagram of a method <NUM> for manufacturing an airfoil system such as the airfoil system <NUM> described above. In step <NUM>, each of the airfoil segments <NUM> is provided. Each airfoil segment <NUM>, for example, may be formed as described above using resin pressure molding (RPM), resin transfer molding (RTM) and/or various other molding process.

In step <NUM>, the electric device <NUM> is attached to a first of the airfoil segment (e.g., 34A). The electric device <NUM>, for example, may be attached (e.g., bonded) to the electric device mount <NUM> of the first airfoil segment (e.g., 34A).

In step <NUM>, the airfoil body <NUM> is assembled. Bonding material, for example, may be applied to one or more mating portions of one or both of the airfoil segments <NUM>. The airfoil segments <NUM> may then be aligned and mated as described above such that the bonding material attaches the airfoil segments <NUM> together. Additional bonding material may also be applied to further secure the electric device <NUM> to the second airfoil segment (e.g., 34B) and its electric device mount <NUM>.

In step <NUM>, the shield <NUM> is configured with the airfoil body <NUM> to provide the airfoil <NUM>. The airfoil body <NUM>, for example, may be mated with and attached to the shield <NUM> as described above.

In some embodiments, the method <NUM> may be modified to include one or more additional steps and/or to omit one or more of the foregoing steps. For example, the method <NUM> may include one or more formation (e.g., machining, cutting, etc.) processes and/or one or more finishing (e.g., sanding, treating, coating, etc.) processes. The method <NUM> may also or alternatively omit the step <NUM> and/or the step <NUM> where, for example, the airfoil <NUM> is configured without the electric device <NUM> and/or the shield <NUM>.

The airfoil body <NUM> and its airfoil segments <NUM> may be constructed substantially (or only) from the non-metallic and/or dielectric material(s) as described above. However, in other embodiments, the internal support structure / airfoil frame (e.g., the internal supports <NUM>, <NUM> and/or <NUM>) may be constructed from metal, or another material that is different than the exterior skin <NUM> material. For example, the exterior skins <NUM> may be constructed from the non-metallic and/or dielectric material, whereas one or more of the internal supports <NUM>, <NUM> and/or <NUM> may be constructed from the other material; e.g., metal. The internal supports <NUM>, <NUM> and/or <NUM>, for example, may be formed discretely and then formed integral with the exterior skins <NUM> in, for example, a similar manner as described above with respect to the segment mounts <NUM>. In such embodiments, each segment mount <NUM> may be formed with a respective one of the internal supports <NUM>, <NUM>, <NUM> as a monolithic (e.g., metal) body or bonded to that internal support after formation. In other embodiments, the (e.g., metal) internal supports <NUM>, <NUM> and/or <NUM> may be bonded to the exterior skins <NUM> following formation thereof. The present disclosure therefore is not limited to any particular materials or construction techniques.

Claim 1:
An airfoil system (<NUM>), comprising:
an airfoil (<NUM>) comprising a first exterior surface (54A), a second exterior surface (54B), a first airfoil segment (34A) and a second airfoil segment (34B) attached to the first airfoil segment (34A), the airfoil (<NUM>) extending widthwise between the first exterior surface (54A) and the second exterior surface (54B), the first airfoil segment (34A) forming the first exterior surface (54A), and the second airfoil segment (34B) forming the second exterior surface (54B); and
an electric device (<NUM>) embedded within the airfoil (<NUM>) between the first airfoil segment (34A) and the second airfoil segment (34B),
wherein:
the airfoil (<NUM>) further comprises an internal cavity (<NUM>) formed collectively by the first airfoil segment (34A) and the second airfoil segment (34B),
the electric device (<NUM>) is located within the internal cavity (<NUM>);
characterised in that:
the electric device (<NUM>) is bonded to at least one of the first airfoil segment (34A) or the second airfoil segment (34B).