Patent Description:
A trailing edge flap of an aircraft wing is operable to increase the lift of the aircraft wing. The trailing edge flap is mounted to the trailing edge of the aircraft wing, and is selectively extended from the trailing edge of the aircraft wing or retracted into the trailing edge of the aircraft wing.

Extending the trailing edge flap from the trailing edge of the aircraft wing increases the surface area on the underside of the aircraft wing. This in turn increases the lift of the aircraft wing. The increased lift of the aircraft wing enables the aircraft to produce a required lift at a lower speed, for example at take-off speed.

Existing trailing edge flaps are constructed using many parts, and many fasteners. For example, an existing trailing edge flap could be constructed with thin aluminum skins extending across the upper surface and the lower surface of the flap and with many internal stiffening elements between the skins. The construction of such a flap with aluminum skins and with many fasteners securing the skins to the many internal stiffening elements is time consuming. The aluminum skins, the many fasteners and the many internal stiffening elements require extensive handling to manufacture the trailing edge flap. Additionally, the aluminum skins, the many fasteners and the many internal stiffening elements of existing trailing edge flaps also contribute to the weight of the trailing edge flap.

Document <CIT>, in accordance with its abstract, states a blade made of layered material, such as composite material, configured for exposure to a fluid flow, comprises skins defined between a leading edge and a trailing edge which skins in cross-section form a flow profile. The layered material may consist of several layers of fiber material impregnated with a matrix material, wherein layers of fiber material each comprise a respective body portion between and transverse to the skins and each at least a respective skin portion that forms part of the skins. The said skin portions all extend from the related body portion in the direction of the trailing edge. Of said skin portions at least two consecutive skin portions of the one skin overlap and/or two consecutive skin portions of the other skin overlap each other.

Document <CIT>, in accordance with its introductory part, states improvements to aerodynamic surfaces and more particularly to helicopter blades.

Document <CIT>, in accordance with its abstract, states a wing leading edge element structure having an elongate piece that comprises a skin plate and at least one longitudinal stiffener. The shape of the front edge of the skin plate is closed and the tail edge is open. The stiffener is fastened between the inner surfaces of the skin plate. Between the inner surface of the skin plate of the outermost longitudinal stiffener, there is a longitudinal space free of transverse stiffeners. The skin plate and stiffeners are manufactured to form an integrated component.

Document <CIT>, in accordance with its abstract, states a method of manufacturing hollow pieces comprising the steps of forming a blank of single sheets each having a layer of gluing substance applied thereto; placing the blank onto an appropriate mandrel and subjecting it to a preliminary compression so as to impart to the blank a stiffness and to shape it into an unclosed profile as required for subsequent steps. Then the blank ends are brought together so as to define a cavity accommodating an elastic bag. The resulting blank is placed into a mould, and pressure is fed into the elastic bag to perform a final pressing.

The trailing edge flap and its method of construction of this disclosure reduces the amount of fasteners and stiffening elements in the construction of the trailing edge flap and reduces the manufacturing time of the trailing edge flap, thereby saving time of manufacture, reducing the cost of manufacture, and reducing the weight of the trailing edge flap.

The trailing edge flap is constructed of nested layers of material including an inner layer, a middle layer and an outer layer. The material is pre-preg composite material, but other types of materials could be used.

The inner layer of material has a folded cover configuration in the aircraft flap that monolithically forms the inner layer of material with a lower panel that is oriented horizontally, an intermediate panel that is oriented vertically and extends upwardly from the lower panel, and an upper panel that is oriented horizontally and extends from the intermediate panel over the lower panel. The lower panel, the intermediate panel and the upper panel extend around a hollow interior volume in the folded over configuration of the inner layer of material.

The middle layer of material has a folded over configuration in the aircraft flap around the inner layer of material. The folded over configuration of the middle layer of material forms the middle layer of material with a lower panel of the middle layer of material that is oriented horizontally and lays over and lays on the lower panel of the inner layer of material, an intermediate panel of the middle layer of material that is oriented vertically and extends upwardly from the lower panel of the middle layer of material and across the hollow interior volume in the folded over configuration of the inner layer of material, and an upper panel of the middle layer of material that is oriented horizontally and extends from the intermediate panel of the middle layer of material and lays over and lays on the upper panel of the inner layer of material.

The outer layer of material has a folded over configuration around the middle layer of material and around the inner layer of material in the aircraft flap. The folded over configuration of the outer layer of material monolithically forms the outer layer of material with a lower panel of the outer layer of material that is oriented horizontally and lays over and lays on the lower panel of the middle layer of material, an intermediate panel of the outer layer of material that is oriented vertically and extends upwardly from the lower panel of the outer layer of material and over the intermediate panel of the middle layer of material, and an upper panel of the outer layer of material that is oriented horizontally and extends from the intermediate panel of the outer layer of material and lays over and lays on the upper panel of the middle layer of material.

The intermediate panel of the inner layer of material forms a first spar in the interior of the aircraft flap, for example a rear spar. The intermediate panel of the middle layer of material forms a second spar in the interior of the aircraft flap, for example a front spar. The intermediate panel of the outer layer of material forms a portion of an exterior of the aircraft flap, for example a bullnose or a rounded, convex surface of the aircraft flap.

There are a plurality of holes through the lower panel of the middle layer of material. There are also a plurality of holes through the upper panel of the middle layer of material. The pluralities of holes have polygonal configurations, and the edges of the plurality of holes are positioned parallel with fibers of the composite material of the middle layer of material. These pluralities of holes remove composite material from the construction of the middle layer of material and reduce the weight of the aircraft flap.

There is an internal support structure in the hollow interior volume of the folded over configuration of the inner layer of material. The internal support structure includes a first rib in the hollow interior volume in the folded over configuration of the inner layer of material. The first rib is secured to the inner layer of material. The internal support structure also includes a second rib in the hollow interior volume in the folded over configuration of the inner layer of material. The second rib is secured to the inner layer of material. The internal support structure further includes an intermediate spar or a midspar in the hollow interior volume in the folded over configuration of the inner layer of material. The midspar is positioned between the first spar and the second spar. The midspar extends between the first rib and the second rib and is secured to the first rib and the second rib.

The aircraft flap construction method involves nesting the layers of composite material, the inner layer, the middle layer and the outer layer in the aircraft flap. The layers of composite material are layers of pre-preg composite material. Other types of composite materials could be used.

The construction method involves laying up the inner layer of material in a folded over configuration around a central mandrel that monolithically forms the inner layer of material with a lower panel, an intermediate panel that extends upwardly from the lower panel and an upper panel that extends from the intermediate panel over the mandrel and over the lower panel. The lower panel, the intermediate panel and the upper panel of the inner layer of material extending around the central mandrel form the inner layer of material extending around a hollow interior volume in the folded over configuration of the inner layer of material.

The construction method further involves laying up the middle layer of material in the folded over configuration around the inner layer of material that monolithically forms the middle layer of material with a lower panel of the middle layer of material that lays over and lays on the lower panel of the inner layer of material, an intermediate panel of the middle layer of material that extends across the hollow interior volume in the folded over configuration of the inner layer of material, and an upper panel of the middle layer of material that lays over and lays on the upper panel of the inner layer of material.

The construction method still further involves laying up the outer layer of material in a folded over configuration around the middle layer of material that monolithically forms the outer layer of material with a lower panel of the outer layer of material that lays over and lays on the lower panel of the middle layer of material, an intermediate panel of the outer layer of material that extends over the intermediate panel of the middle layer of material, and an upper panel of the outer layer of material that lays over and lays on the upper panel of the intermediate layer of material.

Prior to the middle layer of material being laid up in the folded over configuration around the inner layer of material, a plurality of holes are formed through the lower panel of the middle layer of material and through the upper panel of the middle layer of material. The pluralities of holes have polygonal configurations, and edges of the plurality of holes are positioned parallel with fibers of the composite material of the middle layer of material. The composite material removed from the lower panel of the middle layer of material and the upper panel of the middle layer of material reduces the weight of the aircraft flap.

Forming the intermediate panel of the inner layer of material as a first spar, for example a rear spar of the aircraft flap and forming the intermediate panel of the middle layer of material as a second spar, for example a front spar of the aircraft flap minimizes the internal support structure of the aircraft flap and simplifies the laminate design.

Details of the features, functions, and advantages that have been discussed can be seen with reference to the following description and drawings.

<FIG> is a representation of a perspective view of the trailing edge flap <NUM> of this disclosure. The trailing edge flap <NUM> is constructed of nested layers of composite material including an inner layer <NUM>, a middle layer <NUM> and an outer layer <NUM>. In this disclosure, the composite material of each of the inner layer <NUM>, the middle layer <NUM> and the outer layer <NUM> is pre-preg composite material. However, other types of composite materials could be employed in constructing the layers to be described.

<FIG> is a representation of a perspective view of the inner layer <NUM> of material removed from the construction of the trailing edge flap <NUM> of <FIG>. The inner layer <NUM> of material could be a single sheet or single ply of composite material such as pre-preg composite material, or several plies of composite material. The inner layer <NUM> of material has a general rectangular configuration with a longitudinal length that extends between an inboard edge <NUM> and an opposite outboard edge <NUM> of the inner layer <NUM> of material, and a lateral width between a lower edge <NUM> and an opposite upper edge <NUM> of the inner layer <NUM> of material. The longitudinal length of the inner layer <NUM> of material will extend along the longitudinal length of the trailing edge flap <NUM> to be constructed. The relative length and width dimensions of the inner layer <NUM> of material represented in <FIG> are only examples. The relative length and width dimensions of the inner layer <NUM> will change, depending on the length and width dimensions of the trailing edge flap being constructed. As represented in <FIG>, the inner layer <NUM> of material is formed in a folded over configuration. By "folded over configuration", what is meant is that a portion of the inner layer <NUM> of material adjacent the upper edge <NUM> is doubled over or positioned over a portion of the inner layer <NUM> of material adjacent the lower edge <NUM>. The folded over configuration of the inner layer <NUM> of material represented in <FIG> is achieved by folding the inner layer <NUM> of material over a central mandrel.

<FIG> is a representation of an end elevation view of the inner layer <NUM> of material folded over a central mandrel <NUM>. The central mandrel <NUM> has a bottom surface <NUM> and an opposite top surface <NUM>, a first side surface <NUM> and an opposite second side surface <NUM>. The central mandrel <NUM> will have a length dimension depending on the length dimension of the trailing edge flap being constructed. As represented in <FIG>, the inner layer <NUM> of material is folded over the central mandrel <NUM> to form the folded over configuration of the inner layer <NUM>. The folded over configuration of the inner layer <NUM> of material forms the inner layer with a lower panel <NUM> on the bottom surface <NUM> of the central mandrel <NUM>, an intermediate panel <NUM> on the first side surface <NUM> of the central mandrel and an upper panel <NUM> on the top surface <NUM> of the central mandrel <NUM>. Folding the inner layer <NUM> of material on the central mandrel <NUM> monolithically forms the inner layer <NUM> of material with the lower panel <NUM> oriented horizontally, the intermediate panel <NUM> oriented vertically and extending upwardly from the lower panel <NUM>, and the upper panel <NUM> oriented horizontally and extending from the intermediate panel <NUM> over the lower panel <NUM>. The lower panel <NUM>, the intermediate panel <NUM> and the upper panel <NUM> of the inner layer <NUM> of material extend around a hollow interior volume <NUM> in the folded over configuration of the inner layer <NUM> of material.

<FIG> is a representation of a perspective view of the middle layer <NUM> of material removed from the construction of the trailing edge flap <NUM> of <FIG>. As with the inner layer <NUM> of material, the middle layer <NUM> of material could be a single sheet or single ply of composite material such as pre-preg composite material, or several plies of composite material. The representation of the middle layer <NUM> of material in <FIG> has a general rectangular configuration with a longitudinal length that extends between an inboard edge <NUM> and an opposite outboard edge <NUM> of the middle layer <NUM> of material, and a lateral width between a lower edge <NUM> and an opposite upper edge <NUM> of the inner layer <NUM> of material. The rectangular configuration of the middle layer <NUM> of material is only one example of a possible configuration. The configuration of the middle layer <NUM> of material will change depending on the configuration of the trailing edge flap being constructed. As with the inner layer <NUM> of material, the longitudinal length of the middle layer <NUM> of material will extend along the longitudinal length of the trailing edge flap <NUM> to be constructed. The relative length and width dimensions of the middle layer <NUM> of material represented in <FIG> are only examples. The relative length and width dimensions of the middle layer <NUM> of material will change, depending on the length and width dimensions of the trailing edge flap being constructed. As represented in <FIG>, the middle layer <NUM> of material is formed in a folded over configuration. By "folded over configuration", what is meant is that a portion of the middle layer <NUM> of material adjacent the upper edge <NUM> is doubled over or positioned over a portion of the middle layer <NUM> of material adjacent the lower edge <NUM>. The folded over configuration of the middle layer <NUM> of material represented in <FIG> is achieved by folding the middle layer <NUM> of material over the inner layer <NUM> of material on the central mandrel <NUM>.

<FIG> is a representation of an end elevation view of the middle layer <NUM> of material folded over the inner layer <NUM> of material which has been previously folded over the central mandrel <NUM>. Prior to the middle layer <NUM> being folded over the inner layer <NUM>, a release agent is applied onto the lower panel <NUM> of the inner layer, the intermediate panel <NUM> of the inner layer and the upper panel <NUM> of the inner layer. The middle layer <NUM> is then folded over the inner layer <NUM> to form the folded over configuration of the middle layer <NUM>. The folded over configuration of the middle layer <NUM> of material forms the middle layer with a lower panel <NUM> that lays over and lays on the lower panel <NUM> of the inner layer <NUM>, an intermediate panel <NUM> that lays over and lays on the second side surface <NUM> of the central mandrel <NUM>, and an upper panel <NUM> that lays over and lays on the upper panel <NUM> of the inner layer <NUM>. Forming the middle layer <NUM> of material on the inner layer <NUM> of material that has been previously folded over the central mandrel <NUM> monolithically forms the middle layer <NUM> of material with the lower panel <NUM> of the middle layer oriented horizontally, the intermediate panel <NUM> of the middle layer oriented vertically and extending upwardly from the lower panel <NUM> of the middle layer, and the upper panel <NUM> oriented horizontally and extending from the intermediate panel <NUM> over the lower panel <NUM> of the middle layer and on the upper panel <NUM> of the inner layer <NUM>. The lower panel <NUM>, the intermediate panel <NUM> and the upper panel <NUM> of the middle layer <NUM> of material extend around the inner layer <NUM> of material and around the hollow interior volume <NUM> in the folded over configuration of the inner layer <NUM> of material.

As represented in <FIG>, there are a plurality of holes <NUM> through the lower panel <NUM> of the middle layer <NUM>. Each of the holes in the plurality of holes <NUM> has a polygonal configuration. There is also a plurality of holes <NUM> formed through the upper panel <NUM> of the middle layer <NUM>. Each of the holes in this plurality of holes <NUM> also has a polygonal configuration. The pluralities of holes <NUM>, <NUM> are formed in the middle layer <NUM> of material at a later manufacturing step of the middle layer of material. The plurality of holes <NUM>, <NUM> remove composite material from the construction of the middle layer <NUM> of material and thereby reduce the weight of the middle layer <NUM> of material and the weight of the trailing edge flap <NUM> constructed with the middle layer <NUM> of material.

<FIG> is a representation of a perspective view of the outer layer <NUM> of material removed from the construction of the trailing edge flap <NUM> of <FIG>. As with the inner layer <NUM> of material and the middle layer <NUM> of material, the outer layer <NUM> of material could be a single sheet or single ply of composite material such as pre-preg composite material, or several plies of composite material. As represented in <FIG>, the outer layer <NUM> of material has a general rectangular configuration with a longitudinal length that extends between an inboard edge <NUM> and an opposite outboard edge <NUM> of the outer layer <NUM> of material and a lateral width between a lower edge <NUM> and an opposite upper edge <NUM> of the outer layer <NUM> of material. The longitudinal length of the outer layer <NUM> of material will extend along the longitudinal length of the trailing edge flap to be constructed. The relative length and width dimensions of the outer layer <NUM> of material represented in <FIG> are only examples. The relative length and width dimensions of the outer layer <NUM> of material will change, depending on the length and width dimensions of the trailing edge flap being constructed. As represented in <FIG>, the outer layer <NUM> of material is formed in a folded over configuration. By "folded over configuration", what is meant is that a portion of the outer layer <NUM> of material adjacent the upper edge <NUM> is doubled over or positioned over a portion of the outer layer <NUM> of material adjacent the lower edge <NUM>. The folded over configuration of the outer layer <NUM> of material represented in <FIG> is achieved by folding the outer layer <NUM> of material over the middle layer <NUM> of material, over the inner layer <NUM> of material and over the central mandrel <NUM>.

Prior to the outer layer <NUM> of material being folded in its folded over configuration on the middle layer <NUM> of material, the inner layer <NUM> of material and the central mandrel <NUM>, a forward mandrel <NUM> and an aft mandrel <NUM> are added to the central mandrel <NUM>.

As represented in <FIG>, the forward mandrel <NUM> has a flat rear surface <NUM> that is positioned against the middle layer intermediate panel <NUM>. The forward mandrel <NUM> also has a front surface <NUM> that projects outwardly from the flat rear surface <NUM>. The front surface <NUM> has a general semi-circular configuration in cross-section. The forward mandrel <NUM> will have a length dimension depending on the length dimension of the trailing edge flap being constructed.

The aft mandrel <NUM> has a front surface <NUM> that is positioned against the intermediate panel <NUM> of the inner layer <NUM>. The aft mandrel <NUM> has rear surfaces <NUM> that project rearwardly from the front surface <NUM>. The rear surfaces <NUM> give the aft mandrel <NUM> a triangular configuration in cross-section. The aft mandrel <NUM> will have a length dimension depending on the length dimension of the trailing edge flap being constructed.

<FIG> is a representation of an end elevation view of the outer layer <NUM> of material folded over the forward mandrel <NUM>, the middle layer <NUM> of material folded over the inner layer <NUM> of material and the central mandrel <NUM>, and the aft mandrel <NUM>. Prior to the outer layer <NUM> of material being folded over the forward mandrel <NUM>, the middle layer <NUM> of material and the aft mandrel <NUM>, a release agent, for example a release film is applied over the forward mandrel front surface <NUM>, the middle layer lower panel <NUM>, the middle layer upper panel <NUM> and the aft mandrel rear surfaces <NUM>. As represented in <FIG>, the outer layer <NUM> of material is folded over the forward mandrel <NUM>, the middle layer lower panel <NUM>, the middle layer upper panel <NUM> and the aft mandrel <NUM> to form the folded over configuration of the outer layer <NUM> of material. The folded over configuration of the outer layer <NUM> forms the outer layer with a lower panel <NUM> that lays over and lays on the lower panel <NUM> of the middle layer <NUM> and on the rear surface <NUM> of the aft mandrel <NUM>, an intermediate panel <NUM> on the front surface <NUM> of the forward mandrel <NUM>, and an upper panel <NUM> that lays over and lays on the upper panel <NUM> of the middle layer <NUM> of material and on the rear surface <NUM> of the aft mandrel <NUM>. Folding the outer layer <NUM> of material on the forward mandrel <NUM>, the middle layer <NUM> of material and the aft mandrel <NUM> monolithically forms the outer layer <NUM> of material with the lower panel <NUM> oriented horizontally, the intermediate panel <NUM> oriented vertically and extending upwardly from the lower panel <NUM>, and the upper panel <NUM> oriented horizontally and extending from the intermediate panel <NUM> over the lower panel <NUM>. The lower panel <NUM>, the intermediate panel <NUM> and the upper panel <NUM> of the outer layer <NUM> of material extend around the hollow interior volume <NUM> in the folded over configuration of the inner layer of material <NUM>. The inner layer <NUM> of material, the middle layer <NUM> of material and the outer layer <NUM> of material assembled on the central mandrel <NUM>, the forward mandrel <NUM> and the aft mandrel <NUM> as represented in <FIG> are then put through an autoclave process. The autoclave process subjects the inner layer <NUM> of material, the middle layer <NUM> of material and the outer layer <NUM> of material to heat and pressure that cure the inner layer <NUM> of material, the middle layer <NUM> of material and the outer layer <NUM> of material. Following the autoclave process, the inner layer <NUM> of material, the middle layer <NUM> of material and the outer layer <NUM> of material are then removed from the central mandrel <NUM>, the forward mandrel <NUM> and the aft mandrel <NUM>. <FIG> is a representation of end elevation views of the inner layer <NUM> of material, the middle layer <NUM> of material and the outer layer <NUM> of material after removal from the mandrels.

<FIG> is a representation of a perspective view of an internal support structure <NUM> of the trailing edge flap <NUM>. The internal support structure <NUM> includes a first rib <NUM>. The first rib <NUM> is constructed of metal or other equivalent material. The first rib <NUM> has an exterior or peripheral surface configuration that conforms to the interior surface of the inner layer <NUM> of material represented in <FIG>. The internal support structure <NUM> also includes a second rib <NUM>. The second rib <NUM> has an exterior or a peripheral surface configuration that is substantially the same as that of the first rib <NUM>. The second rib <NUM> is also constructed of a metal or other equivalent material. The exterior surface configuration of the second rib <NUM> also conforms to the configuration of the interior surface of the inner layer <NUM> of material as represented in <FIG>. The internal support structure <NUM> further includes an intermediate spar or a midspar <NUM>. The midspar <NUM> is constructed of a composite material or other equivalent material. As represented in <FIG>, the midspar <NUM> extends between the first rib <NUM> and the second rib <NUM> and is secured to the first rib <NUM> and the second rib <NUM>.

In constructing the trailing edge flap <NUM>, the internal support structure <NUM> is positioned in the hollow interior volume <NUM> of the inner layer <NUM> of material. <FIG> is a representation of an end elevation view of the internal support structure <NUM> inserted into the hollow interior volume <NUM> of the inner layer <NUM> of material. The first rib <NUM> is secured to the inner layer <NUM> of material by fasteners, or other equivalent means. The second rib <NUM> is secured to the inner layer <NUM> of material by fasteners or by other equivalent means.

The plurality of holes <NUM> are then formed through the lower panel <NUM> of the middle layer <NUM> of material. The plurality of holes <NUM> represented in <FIG> are also formed through the upper panel <NUM> of the middle layer <NUM> of material. The pluralities of holes <NUM>, <NUM> have polygonal configurations as represented in <FIG>. This positions the edges of the plurality of holes <NUM>, <NUM> parallel with fibers of the composite material of the middle layer <NUM> of material. The pluralities of holes <NUM>, <NUM> remove composite material from the construction of the middle layer <NUM> of material and reduce the weight of the middle layer <NUM> of material and reduce the weight of the trailing edge flap <NUM>. <FIG> is a representation of an elevation, cross-section view through the middle layer <NUM> of material with the plurality of holes <NUM> through the lower panel <NUM> of the middle layer <NUM> of material and the plurality of holes <NUM> through the upper panel <NUM> of the middle layer <NUM> of material.

<FIG> is a representation of an end elevation view of the middle layer <NUM> of material assembled onto the inner layer <NUM> of material that had previously been secured to the internal support structure <NUM> positioned in the hollow interior volume <NUM> of the inner layer <NUM> of material. The middle layer <NUM> of material is assembled onto the inner layer <NUM> of material as represented in <FIG> with a layer of film adhesive between the engaging surfaces of the middle layer <NUM> of material and the inner layer <NUM> of material. Following the autoclave process, the inner layer <NUM> of material, the middle layer <NUM> of material and the outer layer <NUM> of material represented in <FIG> are resilient. This enables the inner layer <NUM> of material, the middle layer <NUM> of material and the outer layer <NUM> of material to be assembled to each other.

With the middle layer <NUM> of material assembled in its folded over configuration on the inner layer <NUM> of material, the outer layer <NUM> of material is assembled in its folded over configuration on the middle layer <NUM> of material. Prior to the outer layer <NUM> of material being assembled on the middle layer <NUM> of material, a film of adhesive is applied between the engaging surfaces of the outer layer <NUM> of material and the middle layer <NUM> of material. <FIG> is a representation of an end view of the outer layer <NUM> of material assembled on the middle layer <NUM> of material. With the outer layer <NUM> of material assembled on the middle layer <NUM> of material as represented in <FIG>, a wedge piece <NUM> of composite material is positioned between the lower panel <NUM> of the outer layer <NUM> of material and the upper panel <NUM> of the outer layer <NUM> of material at the lower edge <NUM> of the outer layer <NUM> of material and the upper edge <NUM> of the outer layer <NUM> of material. The positioning of the wedge piece <NUM> is represented in <FIG>.

The assembled internal support structure <NUM>, the inner layer <NUM> of material, the middle layer <NUM> of material, the outer layer <NUM> of material and the wedge piece <NUM> represented in <FIG> are then vacuum bagged and again autoclaved. This forms a secondary cure bond between the inner layer <NUM> of material, the middle layer <NUM> of material, the outer layer <NUM> of material and the wedge piece <NUM>. Following the second autoclave process the construction of the trailing edge flap <NUM> is completed. <FIG> is a representation of a perspective view of the trailing edge flap <NUM> with portions of the outer layer <NUM> and middle layer <NUM> removed to illustrate the construction of the trailing edge flap <NUM>. In the completed construction of the trailing edge flap <NUM>, the intermediate panel <NUM> of the inner layer <NUM> of material forms a first spar or rear spar in the trailing edge flap <NUM>, the intermediate panel <NUM> of the middle layer <NUM> of material forms a second spar or front spar in the trailing edge flap <NUM>, and the intermediate panel <NUM> of the outer layer <NUM> of material forms a bullnose of the trailing edge flap <NUM>.

Although this disclosure describes the construction of the trailing edge flap <NUM>, the concepts of this disclosure can also be employed in constructing other structures of an aircraft. For example, the concepts of this disclosure could be employed in constructing a vertical tail and rudder assembly of an aircraft. <FIG> is a representation of the component parts that would go into the construction of the tail rudder <NUM>. <FIG> is a representation of the inner <NUM> layer of material, the middle layer <NUM> of material and the outer layer <NUM> of material that are each constructed of composite materials, for example pre-preg composite material. The tail rudder <NUM> also has an internal support structure in the form of a plurality of ribs <NUM>. The ribs <NUM> are constructed of metal, or other equivalent material. The inner layer <NUM> of material, the middle layer <NUM> of material, the outer layer <NUM> of material and the ribs <NUM> are assembled together in the same manner as the construction of the trailing edge flap <NUM> to produce the tail rudder <NUM>.

Claim 1:
An aircraft flap (<NUM>) comprising:
nested layers of composite material including an inner layer (<NUM>), a middle layer (<NUM>) and an outer layer (<NUM>);
the inner layer (<NUM>) having a folded over configuration in the aircraft flap (<NUM>) that monolithically forms a lower panel (<NUM>), an intermediate panel (<NUM>) that extends upwardly from the lower panel and an upper panel (<NUM>) that extends from the intermediate panel over the lower panel, the lower panel (<NUM>), the intermediate panel (<NUM>) and the upper panel (<NUM>) extend around a hollow interior volume (<NUM>) in the folded over configuration of the inner layer (<NUM>);
the middle layer (<NUM>) having a folded over configuration in the aircraft flap (<NUM>) that monolithically forms a lower panel (<NUM>) of the middle layer (<NUM>) that lays over the lower panel (<NUM>) of the inner layer (<NUM>), an intermediate panel (<NUM>) of the middle layer (<NUM>) that extends across the hollow interior volume (<NUM>) in the folded over configuration of the inner layer (<NUM>), and an upper panel (<NUM>) of the middle layer (<NUM>) that lays over the upper panel (<NUM>) of the inner layer (<NUM>);
the outer layer (<NUM>) having a folded over configuration in the aircraft flap (<NUM>) that monolithically forms a lower panel (<NUM>) of the outer layer (<NUM>) that lays over the lower panel (<NUM>) of the middle layer (<NUM>), an intermediate panel (<NUM>) of the outer layer (<NUM>) that extends over the intermediate panel (<NUM>) of the middle layer (<NUM>), and an upper panel (<NUM>) of the outer layer (<NUM>) that lays over the upper panel (<NUM>) of the middle layer (<NUM>);
a plurality of holes (<NUM>) through the lower panel (<NUM>) of the middle layer (<NUM>);
a plurality of holes (<NUM>) through the upper panel (<NUM>) of the middle layer (<NUM>); wherein each hole of the plurality of holes (<NUM>, <NUM>) has a polygonal configuration, edges of the plurality of holes (<NUM>, <NUM>) being positioned parallel with fibers of the composite material of the middle layer (<NUM>).