Patent ID: 7182293

Claim:
A method of manufacturing a box for an airfoil having an outer skin, the method comprising: forming a first unitary half-shell structure of composite material, the first unitary half-shell structure comprising a first portion of the skin of the airfoil, a plurality of stiffener members extending parallel to the first portion of the skin and configured to support the first portion of the skin, and a plurality of connection members defining connection flanges; forming a second unitary half-shell structure of composite material, the second unitary half-shell structure comprising a second portion of the skin of the airfoil, a plurality of stiffener members extending parallel to the second portion of the skin and configured to support the second portion of the skin, and a plurality of connection members defining connection flanges, each stiffener member of the second half-shell structure corresponding in position to a respective one of the stiffener members of the first half-shell structure, and each connection flange of the second half-shell structure corresponding in position to a respective one of the connection flanges of the first half-shell structure; and connecting each connection flange of the second half-shell structure to the corresponding connection flange of the first half-shell structure, thereby forming the box with the first and second portions of the skin of the airfoil disposed in an opposing configuration and the stiffener members disposed therebetween, wherein said first forming step comprises stitching the stiffener and connection members of the first half-shell structure to the first portion of the skin of the airfoil and curing a matrix material of the first portion of the skin and the stiffener and connection members of the first half-shell structure substantially together, wherein said second forming step comprises stitching the stiffener and connection members of the second half-shell structure to the second portion of the skin of the airfoil and curing a matrix material of the second portion of the skin and the stiffener and connection members of the second half-shell structure substantially together.