Patent ID: 12252245

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth to provide a thorough understanding of the disclosed concepts, which may be practiced without some or all of these particulars. In other instances, details of known devices and/or processes have been omitted to avoid unnecessarily obscuring the disclosure. While some concepts will be described in conjunction with specific examples, it will be understood that these examples are not intended to be limiting.

Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item.

Reference herein to “one or more examples” means that one or more feature, structure, or characteristic described in connection with the example is included in at least one implementation. The phrase “one or more examples” in various places in the specification may or may not be referring to the same example.

As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware which enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function.

Illustrative, non-exhaustive examples of the subject matter, disclosed herein, are provided below.

FIG.1illustrate a perspective view of a composite structure100that includes a first layer110and a second layer120. The first layer110is connected to the second layer120to form a layered structure105. While the composite structure100is shown inFIG.1as a skin panel of an aircraft wing, those skilled in the art will appreciate that the disclosed composite structures100may be used in various applications, including various non-aerospace applications.

In one or more examples, the second layer120of the composite structure100includes a plurality of base portions140and a plurality of beaded portions130. The plurality of base portions140may abut the first layer110within the layered structure105of the composite structure100. The plurality of beaded portions130may protrude from the plurality of base portions140. Therefore, each beaded portion130of the plurality of beaded portions130defines an associated channel135between the first layer110and the second layer120such that the composite structure100includes a plurality of channels135.

In one or more examples, at least one system feature300may be disposed in at least one channel135of the plurality of channels135. The system feature300may be, for example, a wire310, a conduit320, a cable, a tube, optical fiber, or the like. Various other system features300may be received within the plurality of channels135without departing from the scope of the present disclosure.

In one or more examples, the second layer120of the composite structure100may be formed from or may include a composite material. The composite material of the second layer120may include a reinforcement material encapsulated in a polymeric matrix material. As a specific, non-limiting example, the reinforcement material may be (or may include) carbon fibers, glass fibers or the like, while the polymeric matrix material may be (or may include) thermoset (e.g., epoxy) resin. The use of various thermoplastic resins, such as a polyaryletherketone, is also contemplated.

In one or more examples, the layered structure105of the composite structure100defines one or more access openings150. In one variation, the access opening150extends through both the first layer110and the second layer120. In another variation, the access opening150extends through only the first layer110of the layered structure105. In yet another variation, the access opening150extends through only the second layer120of the layered structure105. Therefore, an access opening150may be located in a beaded portion130of the plurality of beaded portions130(FIG.6), on a base portion140of the plurality of base portions140, or the composite structure100includes more than one access opening150wherein at least one access opening150is located in a beaded portion130and at least one access opening150is located on a base portion140.

The at least one access opening150, illustrated inFIG.6, allows for access to a beaded portion130of the plurality of beaded portions130for maintenance. One or more system features300may be located in a beaded portion130of the plurality of beaded portions130. The access opening150allows for the one or more system features300to pass outside of the beaded portion130.

As shown inFIG.1, in one or more examples, the composite structure100may further include an access panel151(FIG.1) sealing at least one access opening150. The access panel151can be fluid-tight such that is keeps fluid from passing through the associated access opening150. The access panel151(fuel dam) is configured to be easily accessible for inspection and repair from outside an aircraft wing170, thus reducing the need to enter a confined space.

In one or more examples, the first layer110of the composite structure100is substantially free of beaded portions130. Alternatively, while not shown in the drawings, the first layer110may include a plurality of beaded portions130and a plurality of base portions140, similar to the second layer120.

In one or more examples, the first layer110of the composite structure100may be formed from or may include a composite material. The composite material of the first layer110may include a reinforcement material encapsulated in a polymeric matrix material. As a specific, non-limiting example, the reinforcement material may be (or may include) carbon fibers, glass fibers or the like, while the polymeric matrix material may be (or may include) thermoset (e.g., epoxy) resin. The use of various thermoplastic resins, such as a polyaryletherketone, is also contemplated.

As best shown inFIGS.2A and2B, in one or more examples, the first layer110may define an access opening150providing access to the channel135(FIG.1) between the first layer110and the second layer120. Those skilled in the art will appreciate that the composite structure100may include more than one access opening150providing access to the plurality of channels135(FIG.1).

FIG.2AandFIG.2Billustrate two examples of the beaded portions130of the plurality of beaded portions130. Specifically,FIG.2Aillustrates a beaded portion130that is generally hat-shaped in cross-section, whileFIG.2Billustrates a beaded portion130having a generally rounded shape in cross-section.

As shown inFIG.2A, each beaded portion130of the plurality of beaded portions130may include opposed sidewall portions132and a cap portion134extending between the sidewall portions132. In one or more examples, the plurality of base portions140have a nominal first cross-sectional thickness T1, the sidewall portions132have a nominal second cross-sectional thickness T2, the cap portion134has a nominal third cross-sectional thickness T3. In one or more examples, the nominal third cross-sectional thickness T3is substantially greater (e.g., at least 5 percent greater, such as at least 20 percent greater) than the nominal first cross-sectional thickness T1and substantially greater (e.g., at least 5 percent greater, such as at least 20 percent greater) than the nominal second cross-sectional thickness T2. In one or more examples, the nominal first cross-sectional thickness T1is substantially the same as the nominal second cross-sectional thickness T2. In one or more examples, the nominal first cross-sectional thickness T1, the nominal second cross-sectional thickness T2, and the nominal third cross-sectional thickness T3are substantially the same.

As illustrated inFIG.2A, the first layer110has a nominal fourth cross-sectional thickness T4proximate each base portion140of the plurality of base portions140of the second layer120. The first layer110further has a nominal fifth cross-sectional thickness T5below each beaded portion130of the plurality of beaded portions130. In one or more examples, the nominal fifth cross-sectional thickness T5is substantially the same as a sum of the first cross-sectional thickness T1and the nominal fourth cross-sectional thickness T4. The nominal fifth cross-sectional thickness T5is greater than the nominal fourth cross-sectional thickness T4such that the second layer120is configured to self-nest with the first layer110. In one or more examples, the nominal fifth cross-sectional thickness T5is substantially the same as the nominal third cross-sectional thickness T3.

Referring toFIG.2B, when one or more beaded portions130of the plurality of beaded portions130has a rounded shape in cross-section, the rounded beaded portion130may have a nominal width W1and a nominal height H1. In one or more examples, a ratio of the nominal height H1to the nominal width W1may be less than 1. In other examples, a ratio of the nominal height H1to the nominal width W1is approximately 1. In yet other examples, as illustrated inFIG.2B, each beaded portion130of the plurality of beaded portions130is elongated such that it has a generally oval shape.

In one or more examples, as illustrated inFIG.3B, each beaded portion130of the plurality of beaded portions130includes a tapered end cap138that transitions to a base portion140of the plurality of base portions140. The tapered end cap138has a flared geometry to transition from a hat shape or round shape beaded portion130to a generally planar portion of the second layer120. In one or more examples, the tapered end cap138is integrated with the second layer120such that they are a single monolithic body. In one or more examples, the tapered end cap138is formed separately, such as punch formed, and then co-cured with the second layer120for integration.

As illustrated inFIGS.2A and2B, the layered structure105defines a transition region136where the second layer120transitions from a base portion140of the plurality of base portions140to a beaded portion130of the plurality of beaded portions130. In one or more examples, a filler material155is disposed in the transition region136between the first layer110and the second layer120. The filler material155defines a fillet region within the transition region136. In one or more examples, the filler material155is co-cured with at least one of the first layer110or the second layer120of the layered structure105.

FIG.4illustrates a portion of an exemplary embodiment of the second layer120. In one or more examples, the second layer120includes at least one integral flange128. The integral flange128is configured to align with a spar175. In one or more examples, the integral flange128is substantially parallel with a spar175.

In one or more examples, the first layer110and the second layer120of the disclosed composite structure100may be co-cured, thereby yielding the layered structure105of the composite structure100. Alternatively, the layered structure105of the disclosed composite structure100may include an adhesive (not shown) disposed between the first layer110and the second layer120. The adhesive may be positioned between a first major surface112(FIG.2B) of the first layer110and a second major surface122(FIG.2B) of the second layer120along the base portions140of the second layer120.

As illustrated inFIG.3A, disclosed is an aircraft wing170. The aircraft wing170may be generally tapered in shape. In one or more examples, the aircraft wing170includes a lower skin panel190and an upper skin panel180. At least one of the upper skin panel180and the lower skin panel190includes the disclosed composite structure100comprised of a first layer110and a second layer120. The second layer120is connected to the first layer110to form a layered structure105. In one or more examples, the second layer120includes a plurality of base portions140abutting the first layer110. The second layer120further includes a plurality of beaded portions130protruding from the plurality of base portions140. In one or more examples, each beaded portion130of the plurality of beaded portions130defines a channel135between the first layer110and the second layer120. The plurality of beaded portions130may include approximately eight beaded portions130. In one or more examples, at least one system feature300is disposed in the plurality of channels135. The system feature300is one of a wire310, a conduit320, or any other system feature300provided therein.

In one or more examples, as illustrated inFIG.1, both the upper skin panel180and the lower skin panel190have a layered structure105including a first layer110and a second layer120. The second layer120is connected to the first layer110to form the layered structure105. In one or more examples, the second layer120includes a plurality of base portions140abutting the first layer110. The second layer120further includes a plurality of beaded portions130protruding from the plurality of base portions140. In one or more examples, each beaded portion130of the plurality of beaded portions130defines a channel135between the first layer110and the second layer120. The plurality of beaded portions130may include approximately 8 of each beaded portion130. In one or more examples, at least one system feature300is disposed in the plurality of channels135. The system feature300is one of a wire310, a conduit320, or any other system feature300provided therein.

In one or more examples, the aircraft wing170includes a fluid-tight volume177defined, at least partially, by the upper skin panel180, the lower skin panel190, and the spar175. The plurality of channels135are fluidly isolated from the fluid-tight volume177such that no liquid contaminates any system feature300disposed within a channel135of the plurality of channels135. In one or more examples, the aircraft wing170includes at least one rib173disposed between the upper skin panel180and the lower skin panel190. The at least one rib173defines a fluid-tight volume177with the upper skin panel180, the lower skin panel190, and the spar175. In one or more examples, the aircraft wing170includes more than one rib173that define more than one fluid-tight volume177. In one or more examples, at least one fluid-tight volume177is a fuel tank.

FIG.5Aillustrates a flow diagram of a method200for manufacturing a composite structure100. The method200includes depositing210composite material over a tool to form a second layer120. The second layer120includes a plurality of beaded portions130and a plurality of base portions140. In one or more examples, the plurality of beaded portions130define a plurality of channels135.

In one or more examples, the method200includes distributing220a plurality of mandrels over the second layer120to define channels in the plurality of beaded portions130. In one or more examples, the distributing220the plurality of mandrels includes distributing220a plurality of dissolvable mandrels. In one or more examples, the plurality of dissolvable mandrels include a ceramic material. The ceramic material is dissolvable in water. In one or more examples, the plurality of beaded portions130define a plurality of channels135.

In one or more examples, the method200includes depositing230composite material over the second layer120and the plurality of mandrels to form a first layer110. The first layer110is substantially free of beaded portions130.

In one or more examples, the method200includes bonding240the first layer110to the second layer120. The bonding240is achieved by curing253one or more of the first layer110and the second layer120simultaneously or sequentially. Curing253may be performed in an autoclave. In one or more examples, the bonding240includes curing253the first layer110. In one or more examples, the bonding240includes curing253an adhesive disposed between the first layer110and the second layer120. In one or more examples, the bonding240includes curing253the second layer120.

In one or more examples, the method200for manufacturing a composite structure100includes connecting250a first layer110to a second layer120to form a layered structure105. The second layer120of the layered structure105includes a plurality of base portions140abutting the first layer110and a plurality of beaded portions130protruding from the plurality of base portions140. In one or more examples, each beaded portion130of the plurality of beaded portions130defines a channel135between the first layer110and the second layer120.

In one or more examples, the connecting250includes co-curing259the first layer110and the second layer120to form a layered structure105.

FIG.5Billustrates one exemplary embodiment of the connecting250. In one or more examples, the connecting250includes separately curing253the first layer110and the second layer120to yield a cured first layer110′ and a cured second layer120′. The connecting250further includes bonding255the cured first layer110′ to the cured second layer120′ to form a layered structure105.

FIG.5Cillustrates another exemplary embodiment of the connecting250. In one or more examples, the connecting250includes curing one of the first layer110and the second layer120to yield a cured layer106and an uncured layer108. The connecting250further includes applying257an adhesive between the cured layer106and the uncured layer108. The connecting250further includes co-curing259the adhesive and the uncured layer108to form a layered structure105.

Examples of the subject matter disclosed herein may be described in the context of aircraft manufacturing and service method1100as shown inFIG.7and aircraft1102as shown inFIG.8. During pre-production, illustrative method1100may include specification and design (block1104) of aircraft1102and material procurement (block1106). During production, component and subassembly manufacturing (block1108) and system integration (block1110) of aircraft1102may take place. Thereafter, aircraft1102may go through certification and delivery (block1112) to be placed in service (block1114). While in service, aircraft1102may be scheduled for routine maintenance and service (block1116). Routine maintenance and service may include modification, reconfiguration, refurbishment, etc. of one or more systems of aircraft1102.

Each of the processes of illustrative method1100may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and major-system subcontractors; a third party may include, without limitation, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.

As shown inFIG.8, aircraft1102produced by illustrative method1100may include airframe1118with a plurality of high-level systems1120and interior1122. Examples of high-level systems1120include one or more of propulsion system1124, electrical system1126, hydraulic system1128, and environmental system1130. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Accordingly, in addition to aircraft1102, the principles disclosed herein may apply to other vehicles, e.g., land vehicles, marine vehicles, space vehicles, etc.

Apparatus(es) and method(s) shown or described herein may be employed during any one or more of the stages of the manufacturing and service method1100. For example, components or subassemblies corresponding to component and subassembly manufacturing (block1108) may be fabricated or manufactured in a manner similar to components or subassemblies produced while aircraft1102is in service (block1114). Also, one or more examples of the apparatus(es), method(s), or combination thereof may be utilized during production stages (block1108and block1110), for example, by substantially expediting assembly of or reducing the cost of aircraft1102. Similarly, one or more examples of the apparatus or method realizations, or a combination thereof, may be utilized, for example and without limitation, while aircraft1102is in service (block1114) and/or during maintenance and service (block1116).

Different examples of the apparatus(es) and method(s) disclosed herein include a variety of components, features, and functionalities. It should be understood that the various examples of the apparatus(es) and method(s), disclosed herein, may include any of the components, features, and functionalities of any of the other examples of the apparatus(es) and method(s) disclosed herein in any combination.

Although various examples of the disclosed beaded composite structures and methods for manufacturing beaded composite structures have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

Therefore, it is to be understood that the subject matter, disclosed herein, is not to be limited to the specific examples illustrated and that modifications and other examples are intended to be included within the scope of the appended claims. Moreover, although the foregoing description and the associated drawings describe examples of the subject matter, disclosed herein, in the context of certain illustrative combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative implementations without departing from the scope of the appended claims. Accordingly, parenthetical reference numerals in the appended claims are presented for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided herein.