GB2586495A

GB2586495A - Gap Filler

Info

Publication number: GB2586495A
Application number: GB1912018.7A
Authority: GB
Inventors: Gribble Lewis; Ibanez-Gil German
Original assignee: Airbus Operations Ltd
Current assignee: Airbus Operations Ltd
Priority date: 2019-08-21
Filing date: 2019-08-21
Publication date: 2021-02-24
Anticipated expiration: 2039-08-21
Also published as: GB201912018D0; GB2586495B; WO2021032658A1

Abstract

Filler 1 for at least partially filling a gap 10 or closing an aperture between at least two aircraft components 2, 12 (e.g. wing, wingtip device, stabiliser, parts of fuselage). The gap filler comprises first 3 and second 4 components. The second filler component comprises a channel 5 or a slot. The first component 3 is locatable to a variable extent within the channel to select position of filler components relative to each other. Preferably the second filler component comprises a folded sheet having two parallel legs 4b, 4c and recess 6 for slidably receiving a planar first filler component in a plurality of selectable positions, i.e. the first member 3 is movable within the slot to effect expansion of the filler for different gap sizes in situ. One component may be metal and the other may comprise composite material. The filler components may be removably attachable or permanently glued.

Description

GAP FILLER

TECHNICAL FIELD

[0001] The present invention relates to gap fillers, systems and methods for at least partially filling gaps between aircraft components

BACKGROUND

[0002] During the construction of aircraft, or parts of aircraft, tolerances in the components can cause steps and gaps to appear between various components. If these gaps are in aerodynamics surfaces, they may have a negative impact on the aerodynamic performance. Moreover, the presence of steps and gaps can lead to the accumulation of debris and is aesthetically undesirable. It is therefore desirable to remove, or significantly reduce, the size and number of steps and gaps between aircraft components.

SUMMARY

[0003] A first aspect of the present invention provides a gap filler configured to at least partially fill a gap between at least two aircraft components, the gap filler comprising: a first component; and a second component comprising a channel; wherein the first component is configured to be locatable to a variable extent within the channel, so that a position of the first component relative to the second component can be selected so that the gap filler at least partially fills the gap.

[0004] Optionally, the channel is configured to slidably receive the first component [0005] Optionally, the first component is substantially planar.

[0006] Optionally, at least one of the first component and the second component is a metallic component.

[0007] Optionally, the metallic component comprises tin.

[0008] Optionally, at least one of the first component and the second component comprises a composite material.

[0009] Optionally, the second component comprises a folded sheet of material, is machined, is moulded, is additive-manufactured, or is formed from plural individual parts that are joined together.

[0010] Optionally, the second component is removably attachable to the first component [0011] A second aspect of the present invention provides a system comprising: a first aircraft component, a second aircraft component, and a gap therebetween; and a gap filler that is located at least partially in the gap between the first arid second aircraft components, wherein the gap filler comprises: a first component; and a second component comprising a channel; wherein the first component is fixed relative to the second component at one position of a plurality of selectable positions within the channel, the one position selected so that the gap filler at least partially fills the gap.

[0012] Optionally, the gap filler is configured to define a surface profile that substantially smoothly joins surface profiles defined by the respective first and second aircraft components.

[0013] Optionally, the second component is configured to be removably attachable to at least one of the first and second aircraft components.

[0014] Optionally, the first component is configured to be removably attachable to at least one of the first and second aircraft components [0015] Optionally, at least one of the first and second aircraft components comprises a recess formed in an exterior surface, the recess being in communication with the gap, wherein the second component is at least partially located within the recess.

[0016] Optionally, the second component is configured to be removably attached to the one of the first and second aircraft components.

[0017] Optionally, at least one of the first and second aircraft components comprises an aerodynamic surface.

[0018] Optionally, the gap filler is any gap filler described herein.

[0019] A third aspect of the present invention provides a filler configured to at least partially close an aperture formed between at least two aircraft components, the filler comprising: a first member; and a second member comprising a slot; wherein, when the filler is located in the aperture, the first member is movable within the slot to effect expansion of the filler to at least partially close the aperture; and wherein at least one of the first member and the second member is fixable to at least one of the at least two aircraft components after of expansion of the filler.

[0020] A fourth aspect of the present invention provides an aircraft comprising a gap filler according to the first aspect of the invention, a system according to the second aspect of the present invention, or a filler according to the third aspect of the present invention.

[0021] A fifth aspect of the present invention provides a method of at least partially filling a gap between at least two aircraft components, the method comprising: positioning a gap filler at least partially in the gap, wherein the gap filler comprises a first component and a second component, wherein the second component comprises a channel, and wherein the first component is locatable to a variable extent within the channel; relatively moving the first component and the second component so that the gap filler at least partially fills the gap; and securing at least one of the first component and the second component relative to at least one of the at least two aircraft components.

[0022] Optionally, the positioning comprises at least partially locating the second component in a recess formed in an exterior surface of at least one of the at least two aircraft components, the recess being in communication with the gap.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [0024] Figure 1 shows a schematic side view of one embodiment of the invention.

[0025] Figure 2 shows the schematic side view of Figure 1 but without the gap filler present.

[0026] Figure 3 shows a schematic side view of another embodiment of the invention.

[0027] Figure 4 shows a flow diagram of a method of one embodiment of the invention. [0028] Figure 5 shows a schematic isometric view of an aircraft

DETAILED DESCRIPTION

[0029] In prior arrangements, when a gap or step is present between aircraft components, it is known to fill this gap with a sealant (e.g. epoxy resin). However, this process can be time-consuming, as it requires manually filling all of the gaps and/or steps and then waiting for the sealant to dry. Multiple applications of the sealant may be required if the gaps and/or steps are not satisfactorily filled or covered as a result of the first application. It also leads to an unsatisfactory aesthetic appearance of the aircraft components. Moreover, when an aircraft component needs to be removed to be serviced or replaced, the sealant must be fully removed and then reapplied when the aircraft component is reattached. Again, this can be very time-consuming.

[0030] The presence of gaps and/or steps between aircraft components is particularly unwanted in aerodynamic surfaces (e.g. aircraft wings) Any irregularity in the aerodynamic surfaces can have a direct impact on the aerodynamic performance and/or efficiency of those components.

[0031] Figure 1 shows a schematic side view of a gap filler 1 to at least partially fill a gap 10, or close an aperture, between at least two aircraft components. In this example, the at least two aircraft components are first and second aircraft components 2, 12. The aircraft components may, for example, be portions of an aerodynamic structure that at least partially defines one or more aerodynamic surfaces, such as a wing or a wingtip device or a stabiliser. The aircraft components may be parts of a fuselage. The gap filler 1 comprises a first component 3 (also called a first member 3, herein) and a second component 4 (also called a second member 4, herein). The second component 4 has a channel 5 or slot. More specifically, the second component 4 comprises an intermediate portion 4a and first and second legs 4b, 4c depending from the intermediate portion 4a. In this example, the legs 4b, 4c both depend in parallel and in the same direction from the intermediate portion 4a, but in other examples the legs 4b, 4c may not be parallel. In this example, the first leg 4b depends from the intermediate portion 4a less than the second leg 4c, but in other examples the lengths of the legs 4b, 4c may be equal. The channel 5 is defined by and between the intermediate portion 4a and the legs 4b, 4c. The first component 3 is configured to be locatable to a variable extent within the channel 5, so that a position of the first component 3 relative to the second component 4 can be selected so that the gap filler 1 at least partially fills the gap 10 In other words, the first member 3 is movable within the slot 5 to effect expansion of the gap filler 1 to at least partially close the gap 10 or aperture.

[0032] As shown in Figure 1, the first aircraft component 2 may comprise a recess 6 formed in an exterior surface 2a thereof. The second component 4 of the gap filler 1 may be at least partially positioned within the recess 6 of the aircraft component 2, and may protrude from the recess 6 as shown in Figure 1. In Figure 1, the first leg 4b protrudes above both a first 2 of the aircraft components and the first component 3, when the gap filler 1 is located in the recess 6. The height of protrusion 8 of the first leg 4b may be substantially smaller than the height of the recess 6, however, as shown in Figure 1. As such, the resultant interruption to airflow over the exterior surfaces of the aircraft components and the gap filler 1 should be less than were the gap filler 1 to be omitted.

[0033] Figure 2 shows the schematic side view of Figure 1, but without the gap filler I present for clarity. As shown in Figure 2, the recess 6 is in communication with the gap 10 and is provided for at least partially receiving the gap filler I, and more specifically at least partially receiving the second component 4 of the gap filler 1 Like features are labelled with the same numbers in Figures 1 and 2.

[0034] In some examples, the recess 6 is omitted and the second component 4 is configured to be locatable at least partially within the gap 10 itself In some such examples, the first component 3 and/or the second component 4 may be fixable to the first and/or second aircraft component 2, 12.

[0035] Figure 3 shows a schematic side view of a gap filler 11 which is similar to that of Figure I. Like features are labelled with the same numbers in Figures I and 3.

[0036] As shown in Figure 3, an upper groove 9 may be provided in an upper or outer surface of the first component 3. Advantageously, the upper groove 9 may fully (as shown), or at least partially, receive the first leg 4b of the second component 4. A substantially continuous surface from the first aircraft component 2 to the second component 4 may be created. In other words, an upper or outer surface of the first leg 4b of the second component 4 may lie in substantially the same plane as the exterior surface 2a of the first aircraft component 2. This is advantageous when the exterior surface 2a is an aerodynamic surface of the first aircraft component 2, as it may lead to better aerodynamic performance and/or efficiency. The upper or outer surface of the first leg 4b of the second component 4 may also lie in substantially the same plane as an exterior surface 3a of the first component 3, as shown in Figure 3. Again, this may lead to still better aerodynamic performance and/or efficiency.

[0037] The first leg 4b may not completely fill the upper groove 9, so that part of the upper groove 9 remains exposed, as shown in Figure 3. However, the depth of the upper groove 9 should be substantially smaller than the height of the recess 6, and so the resultant interruption to airflow over the exterior surfaces of the aircraft components 2, 12 and the gap filler 1 should be less than were the gap filler Ito be omitted. In some embodiments, the upper groove 9 is omitted.

[0038] As shown in Figure 3, a lower groove 7 may be provided in a lower or inner surface of the first component 3. Advantageously, the lower groove 7 may fully (as shown), or at least partially, receive the second leg 4c of the second component 4. Advantageously, this may help allow the upper or outer surface 3a of the first component 3 to be flush, or more flush, with the respective exterior surfaces 2a of the first and second aircraft components 2. In some embodiments, the lower groove 7 is omitted.

[0039] In some embodiments, as shown in Figures 1 and 3, the channel 5 is configured to slidably receive the first component 3. Advantageously, the first component 3 can slide to a varying degree within the channel 5 to allow the same gap filler 1 to be used for different sized gaps 10. The first component 3 may be fixed at one position of a plurality of selectable positions within the channel 5, the one position being selected so that the gap filler 1, 11 at least partially fills the gap 10. Alternatively or additionally, the second component 4 may receive the first component in any other way. For example, the second component 4 may be provided in two portions which are combined to create the channel 5. In this case, the first component 3 may be placed in a first portion of the second component 4, and then the second portion of the second component 4 may be attached, to the first portion and/or to the first component 3. As shown in Figures 1 and 3, the second component 4 may include a chamfered section 14 at the juncture of the intermediate portion 4a and the second 4c. Advantageously, this allows the second component 4 to snugly fit in the recess 6, even if a corresponding corner 13 of recess 6 is not perfectly squared. In some examples, the chamfered section 14 may be replaced with a filleted section. In some examples, the second component 4 may not include such a chamfered or filleted section 14.

[0040] In some embodiments, the first component 3 is locatable to a variable extent within the channel 5. This allows a position of the first component 3 relative to the second component 4 to be selected so that the gap filler 1, 11 at least partially fills the gap 10. Advantageously, this allows the gap filler 1, 11 to be used with multiple different gap sizes and to be adjusted in situ, rather than being premade to a specific size of a gap 10.

[0041] in the embodiments of Figures I and 3, the first component 3 is substantially planar. In other embodiments, the first component 3 may be curved or formed in any other shape depending on the gap 10 to be filled or blocked [0042[ In some embodiments, the second component 4 may be a metallic second component. The metallic second component may comprise a metal, such as tin, or a metal alloy. The metallic second component may comprise a mixture of metallic materials or a single metallic material. Alternatively, the metallic second component may entirely or substantially be made of one or more metallic materials. In some embodiments, the first component 3 may be a metallic first component. The metallic first component may have any one of or all of the properties as described above in relation to the metallic second component. For example, the metallic first component may comprise tin.

[0043] In some embodiments, the second component 4 comprises a folded sheet of material. Advantageously, this facilitates manufacture, since only a single component is required to make the second component. Moreover, it allows a single piece of material to be used to create plural different second components 4. This may decrease the cost of manufacturing, as individual tooling or moulds is not required. Alternatively, the second component 4 may be made using additive manufacturing, such as 3D printing. Alternatively, the second component 4 may be machined from a single piece of material. Alternatively, the second component 4 may be formed of plural individual parts that are joined together (e.g. with the application of adhesive or through mechanical fasteners). Alternatively, the second component 4 may be moulded. The way in which the second component 4 is formed may depend on the material and/or geometry of the desired second component 4. Other ways of forming the second component 4 will be apparent to the skilled reader on consideration of the present disclosure.

[0044] In some embodiments, the first component 3 is formed by moulding.

[0045] In some embodiments, the second component 4 is formed of a rigid material. Advantageously, this prevents wrinkling of the second component 4 when it is attached to either the first component 3 or an aircraft component 2, 12 [0046] in some embodiments, at least one of the first component 3 and the second component 4 may comprise a composite material. Advantageously, a composite material may form complex and/or thin shapes which may have a high strength to weight ratio. Moreover, a composite material may have tailored properties. For example, a composite material may be tailored such that it deforms in a predefined direction.

[0047] In some embodiments, the second component 4 may be removably attachable to the first component 3. Advantageously, this may allow the second component 4 to be easily removed from the first component 3 when required. It may also allow the same gap filler 1 to be used multiple times, possibly on multiple different aircraft components. Alternatively, the second component 4 may be permanently attached to the first component 3 after positioning in the channel 5, in order to prevent any subsequent relative movement between the first component 3 and the second component 4. For example, the first component 3 may be affixed to the second component 4 by an adhesive (e.g, glue) or mechanical fastening.

[0048] In some embodiments, a system is provided including: a first aircraft component 2, a second aircraft component 10 and a gap filler 1, 1 1. The gap filler may be any gap filler discussed herein. For example, the gap filler 1, 11 may be one of those shown in Figures 1 or 2. Alternatively, in some embodiments, the gap filler 1, 11 may be provided in isolation, or at least without the first and second aircraft components 2, 12.

[0049] In some embodiments, the recess 6 may be omitted. However, the gap filler 1, 11 may still be configured to block a gap 10 between two aircraft components 2, 12.

[0050] In some embodiments, the gap filler 1, 11 is configured to define a surface profile that substantially smoothly joins surface profiles defined by the respective first and second aircraft components 2, 12. For example, the surface created by the first aircraft component 2, the second aircraft component 12 and the gap filler 1, 11 may be substantially free of gaps or steps. This is advantageous when the first and second aircraft components 2, 12 include aerodynamic surfaces (e.g. aircraft wings), as it may lead to better aerodynamic performance and/or efficiency.

[0051] In some embodiments, the first component 3 may be removably attachable to at least one of the aircraft components 2, 12. Advantageously, this allows the first component 3 to be secured to at least one of the aircraft components 2, 12, while also allowing the first component 3 to be relatively easily removed, e.g. for servicing or replacement.

[0052[ In some embodiments, the second component 4 may be removably attachable to at least one of the aircraft components 2, 12. Advantageously, this allows the second component 4 to be secured to at least one of the aircraft components 2, 12, while also allowing the second component 4 to be relatively easily removed, e.g. for servicing or replacement.

[0053] The first and/or second component 3, 4 may be attachable to one of the aircraft components 2, 12 in a way that prevents movement of the first and/or second component 3, 4 relative to at least one of the aircraft components 2, 12. For example, the first and/or second component 3, 4 may be fastened to the aircraft component 2, 12. Alternatively or additionally, the first and/or second component 3, 4 may be glued to the aircraft component 2, 12.

[0054] In some embodiments, the first component 3 and the second component 4 are secured to the same one of the aircraft components 2, 12 in use. Alternatively, the first component 3 and the second component 4 may be secured to different respective ones of the aircraft components 2, 12. Alternatively, the first component 3 and/or the second component 4 may be secured to more than one of the aircraft components 2, 12.

[0055] In some embodiments, the second component 4 and first component 3 are both secured to an aircraft component 2, 12 through the use of at least one fastener that passes through both the first component 3 and the second component 4 along with the aircraft component 2, 12, where the fastener is secured in place by way of, for example, a mechanical fixing (e.g. a nut, circlip, etc). The second component 4 may define at least one hole, the or each of which is countersunk to receive an associated countersunk portion of the at least one fastener. Advantageously, this may prevent the fastener from protruding from the surface of the second component 4, which may otherwise disrupt airflow.

[0056] In some embodiments, at least one hole may be provided in the second component 4 to receive a respective fastener to secure the second component 4 to the first aircraft component 2. At least one hole may also be provided in the first component 3 to receive the respective fastener, so that the respective fastener passes through both the first and second components 3, 4. The at least one hole in the second component 4 may be through the first leg 4h or through the second leg 4c. The at least one hole in the second component 4 may bc elongated. Advantageously, such elongation allows for a misalignment between the at least one hole in the second component 4 and the at least one hole in the first component 3 which may be caused through manufacturing tolerances. Additionally, the elongate hole in the second component 4 would allow for the position of the first component 3 relative to the second component 4 to be changed, while still allowing the first component 3 and second component 4 to be secured to each other through the use of a fastener which passes through the at least one hole in the second component 4 and the at least one hole in the first component 3.

[0057] In some embodiments, a method of filling a gap between at least two aircraft components 2, 12 is provided. An example such method 30 is shown in Figure 4. The method 30 comprises positioning 31 a gap filler at least partially in the gap 10. The gap filler may be any gap filler 1, 11 described herein, for example, and, in particular, may comprise a first component 3 and a second component 4. The second component 4 has a channel 5 and the first component 3 is locatable to a variable extent within the channel 5. The method 30 also comprises relatively moving 32 the first component 3 and the second component 4 so that a combination of the first component 3 and the second component 4 at least partially fills the gap 10 The method 30 also comprises securing 33 at least one of the first component 3 and the second component 4 relative to at least one of the at least two aircraft components 2, U. [0058] In some embodiments, the positioning comprises at least partially locating the second component in a recess 6 formed in an exterior surface 2a of at least one of the at least two aircraft components 2, 12, the recess 6 being in communication with the gap 10 [0059] As described herein, a gap filler 1, 11 may at least partially fill a gap 10 between at least two aircraft components 2, 12. In some embodiments, the gap filler 1, 11 entirely fills the gap 10 between at least two aircraft components. In some embodiments, the gap filler 1, 11 only partially fills the gap 10 between at least two aircraft components 2, 12 [0060] Figure 5 shows a schematic isometric view of an aircraft 100. The aircraft 100 comprises a gap filler 1, 11 and a system as described herein, in particular a gap filler 1, 11 as discussed herein with reference to Figures 1 and 2. Figure 5 illustrates a gap filler 1 (which may alternatively be gap filler 11) positioned between a first aircraft component 2 and a second aircraft component 12. In Figure 5, the gap filler 1 is shown between two aircraft components 2, 12 on a wing of the aircraft. The gap filler 1 may also be utilised on other parts of the aircraft, for example, a wingtip device or a stabiliser.

[0061] It is to noted that the term "or" as used herein is to be interpreted to mean "and/or", unless expressly stated otherwise [0062] The above embodiments are to be understood as illustrative examples of the invention. It is to be understood that any feature described in relation to any one embodiment may be used alone, or in combination with other features described, and may also be used in combination with one or more features of any other of the embodiments, or any combination of any other of the embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the invention, which is defined in the accompanying claims.

Claims

CLAIMS: 1. A gap filler configured to at least partially fill a gap between at least two aircraft components, the gap filler comprising: a first component; and a second component comprising a channel; wherein the first component is configured to be locatable to a variable extent within the channel, so that a position of the first component relative to the second component can be selected so that the gap filler at least partially fills the gap.
2. The gap filler according to claim 1, wherein the channel is configured to slidably receive the first component.
3 The gap filler according to claim 1 or claim 2, wherein the first component is substantially planar.
4. The gap filler according to any one of the preceding claims, wherein at least one of the first component and the second component is a metallic component.
5. The gap filler according to claim 4, wherein the metallic component comprises tin.
6. The gap filler according to any one of claims 1 to 3, wherein at least one of the first component and the second component comprises a composite material.
7. The gap filler according to any one of the preceding claims, wherein the second component comprises a folded sheet of material, is machined, is moulded, is additive-manufactured, or is formed from plural individual parts that are joined together.
8. The gap filler according to any one of the preceding claims, wherein the second component is removably attachable to the first component A system comprising: a first aircraft component, a second aircraft component, and a gap therebetween; and a gap filler that is located at least partially in the gap between the first and second aircraft components, wherein the gap filler comprises: a first component; and a second component comprising a channel; wherein the first component is fixed relative to the second component at one position of a plurality of selectable positions within the channel, the one position selected so that the gap filler at least partially fills the gap.10. The system according to claim 9, wherein the gap filler is configured to define a surface profile that substantially smoothly joins surface profiles defined by the respective first and second aircraft components 11. The system according to claim 9 or claim 10, wherein the second component is configured to be removably attachable to at least one of the first and second aircraft components.12. The system according to any one of claims 9 to 11, wherein the first component is configured to be removably attachable to at least one of the first and second aircraft components.13. The system according to any one of claims 9 to 12, wherein at least one of the first and second aircraft components comprises a recess formed in an exterior surface, the recess being in communication with the gap, wherein the second component is at least partially located within the recess 14. The system according to claim 13, wherein the second component is configured to be removably attached to the one of the first and second aircraft components.15. The system according to any one of claims 9 to 14, wherein at least one of the first and second aircraft components comprises an aerodynamic surface 16. The system according to any one of claims 9 to 15, wherein the gap filler is according to any one of claims 2 to 8.17. A filler configured to at least partially close an aperture formed between at least two aircraft components, the filler comprising: a first member; and a second member comprising a slot wherein, when the filler is located in the aperture, the first member is movable within the slot to effect expansion of the filler to at least partially close the aperture; and wherein at least one of the first member and the second member is fixable to at least one of the at least two aircraft components after of expansion of the filler.18. An aircraft comprising the gap filler according to any one of claims Ito 8 or the system according to any one of claims 9 to 16 or the filler according to claim 17.19. A method of at least partially filling a gap between at least two aircraft components, the method comprising: positioning a gap filler at least partially in the gap, wherein the gap filler comprises a first component and a second component, wherein the second component comprises a channel, and wherein the first component is locatable to a variable extent within the channel; relatively moving the first component and the second component so that the gap filler at least partially fills the gap; and securing at least one of the first component and the second component relative to at least one of the at least two aircraft components.20. The method of claim 19, wherein the positioning comprises at least partially locating the second component in a recess formed in an exterior surface of at least one of the at least two aircraft components, the recess being in communication with the gap.