Patent ID: 6306239
Filing Date: 2001-10-23
Classification: B29C,B64C,B64F,Y02T

Abstract:
A method of fabricating a stringer-stiffened shell structure including a fiber reinforced composite material, said method comprising the following steps:a) providing a skin member comprising a first fiber reinforced composite material having opposite first and second skin surfaces;b) laying said skin member onto a mold surface of a shell mold so that said first skin surface lies conformingly on said mold surface and said skin member has a skin contour configuration matching a mold surface contour of said mold surface;c) providing a pre-cured strip-shaped stringer core blank comprising a pre-cured second fiber reinforced composite material and having a narrow edge and two opposite broad side faces extending along a strip length;d) arranging said stringer core blank on said skin member which is lying on said mold surface, such that said narrow edge of said stringer core blank lies conformingly in contact on said second skin surface of said skin member and said broad side faces of said stringer core blank extend away from said skin member, and wherein said narrow edge of said stringer core blank has an edge contour configuration matching said skin contour configuration where said narrow edge is in contact with said second skin surface;e) providing a flexibly deformable elongate stiffening profile member which is more flexible than said stringer core blank and which comprises a flexible third fiber reinforced composite material and includes a lengthwise extending base web and a lengthwise extending protruding web that runs along and protrudes from said base web;f) laying said stiffening profile member with said protruding web lying conformingly in contact along one of said broad side faces of said stringer core blank and with said base web lying conformingly in contact along said second skin surface adjacent to said stringer core blank, wherein said stringer core blank acts as a molding form against which said protruding web of said stiffening profile member is conformed during this step f); andg) carrying out a hardening process wherein said stiffening profile member hardens and becomes rigidly and intimately bonded with said stringer core blank and with said skin member, and wherein said stringer core blank becomes a structural strengthening core of a stringer made up of at least said stringer core blank and said stiffening profile member upon completion of this step g).