Patent ID: 7459048
Filing Date: 2008-12-02
Classification: B29C,B29D,B29L,B64C,Y02T,Y10T

Abstract:
1. A method of manufacturing a unitary seamless section of an aircraft fuselage, the method comprising: disposing a plurality of caul plates onto an outer shell surface of a one-piece inner mandrel shell to form a mandrel with a lay-up surface, said caul plates arranged longitudinally parallel to the longitudinal axis of said one-piece inner mandrel shell and comprising a plurality of longitudinal stiffener channels formed into a caul outer surface; laying up a plurality of resin impregnated stiffener fibers within said plurality of stiffener channels to form a plurality of stiffeners; inserting a removable rubber mandrel into each of said plurality of stiffener channels; and laying up a plurality of resin impregnated skin fibers onto said lay-up surface while said mandrel rotates to form a unitary pre-cured section of an aircraft fuselage, wherein the top ends of said plurality of resin impregnated stiffener fibers form a flush mandrel surface and are in contact with said plurality of resin impregnated skin fibers.