Rotor wing with integrated tension-torque-transmission element and method for its production

1. A fibre-reinforced rotor wing for a tail rotor of a rotary wing aircraft, the wing comprising:

a rotor blade having a blade body with an aerodynamic profile and a blade skin;

a tension-torque-transmission element extending from the rotor blade via a blade side connecting section, the blade side connecting section tapering from the rotor blade to the tension-torque-transmission element; and

a hub side connecting section having a connecting eye and extending from a second end of the tension-torque-transmission element;

wherein the blade body, the tension-torque-transmission element, the hub side connecting section and the blade side connecting section are formed by a plurality of unidirectional fibre layers, each fibre layer extending from the hub side connecting section to a tip of the blade body, the fibre layers forming stacked spar tapes;

wherein the tension-torque-transmission element is formed by lamellae of the stacked spar tapes;

wherein additional fibre layers are positioned between the stacked spar tapes in the blade side and hub side connecting sections such that the lamellae are spaced apart from one another in the tension-torque-transmission element; and

wherein the additional fibre layers are scarf joined between the unidirectional fibre layers to provide triangular transition regions between the lamellae and the blade side and hub side connecting sections.

2. The rotor wing according to claim 1 wherein the blade side connecting section has an ellipsoid section adjacent to the rotor blade and a conical section adjacent to the tension-torque-transmission element, the rotor wing further comprising:

a control tube extending from an intermediate region of the tension-torque-transmission element over the blade side connecting section, the control tube having a tubular base body with a control lever radially distant from the tubular base body, the tubular body defining an ellipsoid threaded opening on a blade side and a circular opening on a tension-torque-transmission element side, the tubular body defining an ellipsoid inner cone sized to mate with the ellipsoid section of the blade side connecting section.

3. The rotor wing according to claim 1 further comprising coated films positioned between the spaced apart lamellae, wherein the films prevent the lamellae from adhering to one another and decouple the lamellae from each other to prevent transmission of shearing strain at facing boundary surfaces of adjacent lamellae.

4. The rotor wing according to claim 1 wherein each transition region is adapted to provide a continuous increase in torsional rigidity across the transition region.

5. The rotor wing according to claim 1 wherein the triangular transition regions between the lamellae of the tension-torque-transmission element and the blade side and hub side connecting sections are almost stepless transitions.

6. The rotor wing according to claim 1 wherein the fibre layers of the stacked spar tapes in the blade side connecting section are adapted to rotate 10° to 20°relative to a rotational plane of the rotor blade and corresponding to an angle of incidence of the rotor blade relative to the rotational plane.

7. The rotor wing according to claim 1 , characterised by an essentially rectangular cross section of the stacked spar tapes.

8. The rotor wing according to claim 1 , characterised by a layered and staggered arrangement of the stacked spar tapes in the blade body for forming the aerodynamic blade profile.

9. The rotor wing according to claim 1 , characterised by a different width of the stacked spar tapes depending on their height position in the tension-torque-transmission element.

10. The rotor wing according to claim 1 , characterised in that the additional fabric layers have a fibre orientation of ±45°.

11. The rotor wing according to claim 1 wherein the connecting eye is configured for attachment of the rotor blade to a drive device by way of a bolt that essentially extends perpendicularly to a plane of extension of the tension-torque-transmission element.

12. The rotor wing according to claim 1 further comprising

a separate control tube for transmitting control forces to the rotor wing, with an also essentially cylindrical connecting section for tying the control tube to the rotor blade, characterised in that the blade side connecting section of the rotor wing and the connecting section of the control tube comprise a corresponding cross-sectional shape for positive-locking force transmission of control forces between the rotor blade and the control tube.

13. A method for producing the rotor wing according to claim 1 , from the rotor blade and from the tension-torque-transmission element made of a fibre-reinforced material in the following steps:

a) placing ready-made contoured fibre layers in a mould tool by scarf-join intermediate layers in the tension-torque-transmission element and in the rotor blade;

b) curing the moulded blank under pressure and with heat;

c) milling the cured moulded blank that has been removed from the mould so as to give it its final contour.

14. The method according to claim 13 , characterised in that subsequently in a step d) the connecting eye is made in the cured tension-torque-transmission element.

15. The method according to claim 14 , characterised in that the connecting eye is drilled/milled in the tension-torque-transmission element.