Tubular members integrated to form a structure

• US 20030146346A1
• Filed: 12/09/2002
• Published: 08/07/2003
• Est. Priority Date: 12/09/2002
• Status: Abandoned Application

• Current Assignee: Chapman W. Cullen Jr
• Original Assignee: Chapman W. Cullen Jr
• Inventors: Chapman, W. Cullen Jr.
• Application Number:
  US10/181,592
• Publication Number:
  US 20030146346A1
• Time in Patent Office: Days
• US Class Current: 244/123
• CPC Class Codes: B29C 53/585 the cross-section varying along their axis, e.g. tapered, with ribs, or threads, with socket-ends
• CPC Class Codes: B29C 53/828 Arrangements comprising a plurality of cores or mandrels, e.g. to increase production speed B29C53/827 takes precedence
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/18 using heated tools
• CPC Class Codes: B29C 65/56 using mechanical means or mechanical connections, e.g. form-fits
• CPC Class Codes: B29C 65/58 Snap connection
• CPC Class Codes: B29C 66/12423 Dovetailed interlocking undercuts
• CPC Class Codes: B29C 66/12464 being V-shaped
• CPC Class Codes: B29C 66/54 Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
• CPC Class Codes: B29C 66/63 Internally supporting the article during joining B29C66/49 takes precedence
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/721 Fibre-reinforced materials B29C66/729 takes precedence
• CPC Class Codes: B29C 66/7212 characterised by the composition of the fibres
• CPC Class Codes: B29C 66/72141 Fibres of continuous length
• CPC Class Codes: B29C 70/32 on a rotating mould, former or core
• CPC Class Codes: B29C 70/34 and shaping or impregnating by compression , i.e. combined with compressing after the lay-up operation
• CPC Class Codes: B29D 99/0028 hollow blades
• CPC Class Codes: B29K 2063/00 Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
• CPC Class Codes: B29K 2277/10 Aromatic polyamides [Polyaramides] or derivatives thereof
• CPC Class Codes: B29K 2307/02 : Boron
• CPC Class Codes: B29K 2307/04 : Carbon
• CPC Class Codes: B29K 2309/08 : Glass
• CPC Class Codes: B29L 2031/3076 : Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B29L 2031/3085 : Wings
• CPC Class Codes: B29L 2031/7172 : Fuel tanks, jerry cans
• CPC Class Codes: B32B 3/20 : of hollow pieces, e.g. tubes; of pieces with channels or cavities
• CPC Class Codes: B64C 3/22 : Geodetic or other open-frame structures
• CPC Class Codes: B64F 5/10 : Manufacturing or assembling aircraft, e.g. jigs therefor
• CPC Class Codes: Y02T 50/40 : Weight reduction

Abstract

Integrally stiffened and formed, load carrying structures comprising a plurality of elongated thin-walled tubes placed co-extensively in a complementary side-by-side fashion which together form a hollow structure having a desired external contour. Integral skins forming the external and internal surfaces of the structure cooperatively therewith. The structure can be formed with an underlying internal support member spanning the interior of the load carrying structure, thereby connecting opposite sides of the structure together. Also, each of the tubes are wound with fibers in controlled orientations generally paralleling the direction of the loads applied to the tubes to optimize the strength to weight ratio of the tubes. Still a number of embodiments are disclosed to couple two structures together. In addition, an apparatus and method is disclosed to form a window opening within the fuselage and to install a window covering that is both time saving and cost efficient.

Claims

1. An elongated load carrying structure of a predetermined curved exterior contour comprising:

a wall formed by a plurality of elongated co-extensive triangular cross-section filament wound tubes nested complementally together in juxtaposition and arranged to cooperate together in forming at least a portion of a hollow shell defining a body of revolution having said predetermined exterior contour;

a bond bonding said tubes together; and

an outer skin covering the exterior surface of said shell.

2. An elongated load carrying structure as set forth in claim 1 for carrying a predetermined load wherein:

said tubes are wound with filaments oriented and arranged to efficiently carry said predetermined load.

3. An elongated load carrying structure as set forth in claim 1 wherein said exterior cross section is a fluid foil and wherein:

said tubes are arranged to define the shape of said shell as said fluid foil.

4. An elongated load carrying structure as set forth in claim 1 wherein:

said tubes are wound with filaments having a helical pitch from 0°

to 90°

to the longitudinal axis.

5. An elongated load carrying structure as set forth in claim 1 wherein:

said skin is filament wound.

6. An elongated load carrying structure as set forth in claim 3 wherein:

said foil is in the shape of an airplane wing; and

said tubes are arranged to cooperate in forming a leading edge, round in transverse, also an acute angle trailing edge.

7. An elongated load carrying structure as set forth in claim 1 wherein:

said tubes are hollow to form longitudinal passages therein.

8. An elongated load carrying structure as set forth in claim 1 wherein:

said tubes are formed with respective equilateral cross sections.

9. An elongated load carrying structure as set forth in claim 1 wherein:

said tubes are wound with selected sections having one wall thickness and other sections having a different wall thickness.

10. An elongated load carrying structure as set forth in claim 1 that includes:

a strut device in said shell extending from one side to the other thereof.

11. An elongated load carrying structure as set forth in claim 10 wherein:

said strut device includes elongated filament wound triangular tubes located side by side and nested together.

12. An elongated load carrying structure as set forth in claim 1 wherein said structure is a fuselage and wherein further:

said tubes are arranged to cooperate in forming said shell with a circularly shaped said exterior contour.

13. An elongated load carrying structure as set forth in claim 1 wherein:

said structure is a fluid foil; and

said tubes are arranged to form discrete leading edge and trailing edge sections; and

said skin is arranged to cover said sections.

14. An elongated load carrying structure as set forth in claim 13 wherein:

said leading and trailing edge sections are configured with conforming sides configured with respective abutting sections that abut together and inclined recess sections cooperating to, when said abutting sections are abutted together, form cavities of selected configurations; and

filament wound filler tubes configured for complemental receipt in said cavities.

15. An elongated load carrying structure as set forth in claim 1 wherein:

said tubes are configured with uniform cross sections along the irrespective length.

16. An elongated load carrying structure as set forth in claim 1 wherein said structure is formed to project longitudinally with said exterior contour tapering laterally inwardly in one direction along the length thereof and wherein further:

at least some of said tubes angle laterally inwardly toward one another in said one direction.

17. An elongated load carrying structure as set forth in claim 1 wherein:

said tubes are arranged to configure said wall to form leading and trailing wing sections.

18. An elongated load carrying structure as set forth in claim 17 wherein:

said tubes are arranged to configure said trailing section with top and bottom walls projecting forwardly from a trailing edge and diverging from one another;

said trailing section being configured at its forward extremity with a first coupling;

said leading section being configured with a rounded leading edge with respective top and bottom walls projecting rearwardly; and

said leading section being formed at its rear extremity with a second coupling for complementally coupling with said first section.

19. An elongated load carrying structure as set forth in claim 18 wherein:

said tubes are arranged to form said wall configured to define said first and second couplings.

20. An elongated load carrying structure as set forth in claim 18 wherein:

said first coupling includes lugs mounted on the respective top and bottom walls of said trailing section; and

said second coupling includes a keeper engageable behind said lugs.

21. An elongated load carrying structure as set forth in claim 18 wherein:

said first coupling includes dovetail grooves; and

said second coupling includes tongues complementally received in said grooves.

22. An elongated load carrying structure as set forth in claim 1 wherein:

said tubes are arranged in juxtaposition and in a circular pattern to form said wall as a fuselage section.

23. An elongated load carrying structure as set forth in claim 22 wherein:

said tubes are arranged to configure said wall in a circular pattern and include longitudinal and helical filaments.

24. A structure as set forth in claim 1 wherein:

said tubes are trapezoidal in cross-section.

25. A structure as set forth in claim 1 wherein:

said tubes are arranged to form a wing box.

26. A structure as set forth in claim 1 wherein:

said tubes are arranged to form a hollow wing structure and includes a further plurality of triangular cross-section filament wound tubes juxtaposed in the interior of said wing structure and bonded together to cooperate in forming one or more gussets.

27. A structure as set forth in claim 1 wherein:

said tubes are arranged to cooperate in forming the wall of a wing section; and

said structure further includes a further plurality of elongated co-extensive juxtaposed triangular in cross-section filament wound hollow tubes arranged together to define, in cross-section, a generally crescent shape defining a wing slat to be connected to the front of said wing section.

28. A structure as set forth in claim 1 wherein:

said filament wound tubes are arranged to cooperate in forming the wall of a trailing wing section, and wherein;

said structure includes a plurality of elongated co-extensive triangular in cross-section filament wound hollow tubes arranged to form a slat section configured for attachment to said trailing wing section.

29. A structure as set forth in claim 27 wherein:

further tubes are arranged to form said flap in the form of split flaps.

30. A structure as set forth in claim 1 wherein:

said tubes are arranged to cooperate in forming the entire wall of said shell.

31. A method of making a composite contoured structure for carrying a load and wall of a shell including:

selecting triangular cross-section hollow tubes, filament wound in a pattern;

assembling said tubes together in co-extensive side by side relationship to form the defining predetermined curved cross-sectional exterior contour;

bonding said tubes together;

applying a skin to at least one surface of said shell; and

bonding said skin to said shell.

32. The method of claim 31 that includes:

selecting said tubes configured with a transverse cross section of an isosceles triangle shape.

33. The method of claim 31 that includes:

placing said tubes in a configuration to form said shell in the shape of a fluid foil.

34. The method of claim 31 that includes:

placing tubes to form said shell in the configuration of the cross section of an airplane fuselage.

35. The method of claim 31 that includes:

winding said tubes with filament having first sections with a first wall thickness and second sections with a thicker wall thickness for carrying heavy loads.

36. The method of claim 31 that includes:

arranging said tubes to form said wall of said shell to taper inwardly longitudinally in one direction along the length thereof and wherein;

the step of placing said tubes includes placing at least some of said tubes to angle longitudinally in said one direction and angling inwardly toward the other tubes.

37. The method of claim 31 for forming said structure with said contour as a rounded exterior cross section and that includes:

forming at least selected ones of said tubes with one side wall thereof rounded and positioning said selected tubes so that said rounded sides thereof face exteriorly outwardly in said shell to cooperate in forming said rounded exterior cross section.

38. The method of claim 31 that includes making said structure with an anchor section and that includes:

making a filament wound plug to be complementally received in one of said tubes;

placing said plug in said one of said tubes;

bonding said plug in said tube to form said anchor section.

39. The method of claim 31 that includes:

making said tubes over mandrels having respective walls which taper inwardly from one end to the other.

40. The method of claim 31 for making a fluid foil for connecting to a body and that includes:

making a fitting configured with mounting plugs formed with a predetermined triangular cross section; and

the method of making said tubes includes making at least one end of selected ones of said tubes with an interior cross section constructed to be complementally fitted over respective ones of said plugs.

41. The method of claim 31 wherein:

the step of assembling said tubes includes selecting a mold and placing said tubes against the wall of said mold.

42. The method of claim 41 wherein:

said mold is selected as a male mandrel.

43. The method as set forth in claim 31 wherein:

the bonding of said tubes together includes applying a bond to the confronting walls of said tubes and concurrently curing said bond.

45. The method as set forth in claim 31 wherein:

said tubes are arranged to form first and second discrete sections of a fluid foil; and

a further plurality of said tubes are arranged to form first and second coupling devices connected to the adjacent sides of said first and second discrete parts.

46. The method of claim 31 wherein:

said step of assembling said tubes includes arranging said tubes to form respective first and second walls configured to form first and second discrete hollow sections of an airfoil with adjacent sections thereof being formed with multiple layers of tubes; and

removing selected ones of said tubes in said multiple layers to form respective mechanical interlocking coupling devices.

47. The method of claim 31 wherein:

said tubes are arranged with at least some of said tubes arranged in a plurality of layers.

44. The method as set forth in claim 44 wherein:

said bonding step of said shell is performed concurrent with the bonding of said tubes.

48. A method of making an elongated composite to form a predetermined transverse contour structure and including:

selecting elongated tubes filament wound in a pattern;

assembling said tubes together in juxtaposed relationship to form a shell defining a predetermined transverse contour;

bonding said tubes together;

applying an exterior skin to the exterior surface of said shell; and

bonding said skin to said tubes.

49. A method for producing a triangular tube to resist a predetermined load on the triangular tube, comprising the steps of:

providing a mandrel having a substantially triangular cross-section;

winding the mandrel with fibers in a controlled orientation substantially paralleling the direction of a predetermined load on triangular tube;

bonding the fibers together;

curing the fibers together; and

removing the mandrel within the fibers.

50. A method according to claim 49 wherein the mandrel tapers along the longitudinal axis, forming a tapered triangular fiber wound tube.

51. A method according to claim 49 wherein the mandrel curves along the longitudinal axis, forming a curved triangular fiber wound tape.

52. A method according to claim 49 wherein the fibers are wound in a variety of controlled orientation to resist tensile, compression, and shear stresses.

53. A method according to claim 49 wherein the fibers are bonded by a pre-impregnated matrix material.

54. A method according to claim 49 wherein the pre-impregnated matrix material is an organic material.

55. A method according to claim 49 wherein the pre-impregnated matrix material is a metallic material.

56. A method according to claim 49 wherein the fibers have a substantially triangular cross-section.

57. A method according to claim 49 wherein the mandrel is removed by withdrawing the mandrel.

58. A method according to claim 49 wherein the mandrel is removed by melting the mandrel.

59. A method according to claim 49 wherein the mandrel has a predetermined section with smaller triangular cross-section along the longitudinal axis of the mandrel, wherein fibers are thicker about the predetermined section having smaller triangular cross-section.

60. An intermediate apparatus to couple a composite wing structure having a plurality of elongated thin-walled filament wound tapered triangular tubes placed co-extensively in a complementary side-by-side fashion to a composite fuselage comprising:

a predetermined number of plugs having a root end and a tip end, wherein each of the predetermined number of plugs is tapered to associate with the corresponding tapered triangular tubes;

each of the predetermined number of plugs having a flange, wherein each of the flanges are coupled to the root end of the plugs to align relative to other flanges when plugs are inserted into the corresponding tapered triangular tubes; and

the aligned flanges adapted to associate with a composite fuselage adapted to receive the aligned flanges.

61. A method of making a structure for carrying a load, comprising the steps of:

providing a chamber with gaseous reactant in the chamber;

providing a substrate within the chamber; and

tracing a laser at the substrate around a cross-section of a structure about a predetermined point along the longitudinal axis of the structure defining the structure, wherein a layer of localized deposition of fibers occur from the gas reacting due to the heat generated from the laser beam passing through the cross-sections of the structure along the longitudinal axis.

62. A method according to claim 61, wherein the cross-section of the structure varies along the longitudinal axis.

63. A method according to claim 61, wherein the gaseous reactant is carbon.

64. A method according to claim 61, wherein the structure is an airplane wing structure.

65. A filament having a high content of fibers versus the matrix material, comprising:

a filament including a plurality of cross-section of fibers and a matrix material thereinbetween the plurality of cross-section of fibers; and

said plurality of cross-section of fibers comprise at least approximately 60% of a cross-sectional area of the filament.

66. A filament according to claim 65, wherein:

the plurality of cross-section of fibers are triangular, wherein the plurality of triangular fibers are placed together in alternating side by side relationship, wherein the distance between the adjacent triangular fibers is less than approximately one tenth (0.1) of the width of the triangle.

67. A filament according to claim 65, wherein said plurality of cross-section of fibers comprise at least approximately 90% of a cross-sectional area of the filament.

68. A filament according to claim 65, wherein:

the plurality of cross-section of fibers are square, wherein the plurality of square fibers are placed together in side by side relationship, wherein the distance between the adjacent square fibers is less than approximately one tenth (0.1) of the width of the square.

69. A tie for coupling two triangular tubes made of composite structure, comprising:

a base adapted to be juxtaposed to one of the walls of a first triangular tube made of composite structure; and

a plurality of locking inserts coupled to the base at a predetermined distance apart from each other, wherein each of the locking inserts is adapted to receive a fastener.

70. A tie according to claim 69, wherein the base has edges that are beveled adapted to wedge into an inside wall the side of the two triangular tubes.

71. A tie according to claim 69, wherein the base has a trapezoidal cross-sectional shape.

72. A tie according to claim 69, wherein the base is made of same material as the first triangular tube.

73. A tie according to claim 69, wherein the locking inserts are nuts.

74. A tie according to claim 69, wherein the base has a plurality of holes corresponding to the plurality of locking inserts so that a fastener can go through the hole and tighten against the corresponding locking insert.

75. A tie according to claim 69, wherein the base has a plurality of cavity adapted to receive the plurality of locking inserts so that the plurality of locking inserts are flushed within the base.

76. A tie according to claim 69, wherein the tie is inserted between the first triangular tube and a second triangular tube that are juxtaposed at one end of each other, wherein at least one fastener is inserted through the first triangular tube and a corresponding locking insert within the first triangular tube and at least one fastener is inserted through the second triangular tube and a corresponding locking insert within the second triangular tube to couple the first and second triangular tubes together.

77. A tie according to claim 69, wherein the tie is inserted into the side of the first triangular tube and a second triangular tube is juxtaposed to the first triangular tube side by side, wherein a fastener is inserted through the second and first triangular tubes and tighten against a corresponding locking insert to couple the first and second tubes together.

78. A tie according to claim 69, wherein the base is shaped to contour the joint between two composite structures.

79. A tie according to claim 78, wherein the base substantially forms a L cross-section to contour the joint between the two composite structure that are substantially 90°

from each other.

80. A tie according to claim 78, wherein the base substantially forms a flange to contour the skin of two composite structures that are substantially oblique angle with respect to each other.

81. A system for coupling two composite structures, comprising:

a tie, the tie having a plurality of locking inserts at a predetermined distance apart from each other;

a first composite structure having a first mating outer surface, a first opening within the first composite structure and adjacent to the first mating outer surface of the first composite structure, wherein the first opening is adapted to receive the first tie;

a second composite structure having a second mating outer surface, a second opening within the second composite structure and adjacent to the second mating outer surface of the second composite structure, wherein the first and second mating outer surfaces are adapted to be substantially flushed against each other; and

a first fastener adapted to insert through the first and second mating outer surfaces of the first and second composite structure respectively and tighten against a corresponding locking insert on the tie, thereby coupling the first and second composite structures together.

82. A system according to claim 81, wherein the first composite structure is a wing box.

83. A system according to claim 81, wherein the second composite structure is a leading section.

84. A system according to claim 81, wherein the first opening is a triangular shape opening.

85. A system according to claim 84, wherein the tie has a base, the base having beveled edges adapted to wedge into the triangular shape opening.

86. A system according to claim 81, further including a second tie and a second fastener, wherein the second opening is adapted to receive the second tie, wherein the second fastener adapted to insert through the first and second mating outer surfaces of the first and second composite structure respectively and tighten against a corresponding locking insert on the second tie, thereby coupling the first and second composite structures together..

87. A system for coupling two composite structures, comprising:

a tie having a plurality of locking inserts at a predetermined distance apart from each other;

a first composite structure having a first mating outer surface, a first opening within the first composite structure and adjacent to the first mating outer surface of the first composite structure, wherein the first opening is adapted to receive the tie;

a second structure having a second mating outer surface, a second opening within the second structure and adjacent to the second mating outer surface of the second structure, wherein the first and second mating outer surfaces are adapted to be substantially flushed against each other; and

at least one fastener adapted to insert through the first and second mating outer surfaces of the first and second structures respectively and tighten against a corresponding locking insert on the tie, thereby coupling the first and second structures together.

88. A system according to claim 87, further including a base having a plurality of holes corresponding to the plurality of locking inserts on the tie, the second opening within the second structure adapted to receive the base, whereby the at least one fastener runs through the hole in the base, the first and second mating outer surfaces of the first and second structures respectively and tighten against a corresponding locking insert on the tie to couple the first and second structures together.

89. A system according to claim 87, wherein the first composite structures is formed from a plurality of elongated co-extensive triangular cross-section filament wound tubes nested complementally together in juxtaposition and arranged to cooperate together in forming at least a portion of a hollow shell defining the first mating outer surface.

90. A system according to claim 87, wherein the first composite structure defines a leading section of a wing.

91. A system according to claim 87, wherein the first composite structure defines a wing box.

92. A system according to claim 87, wherein the tie has a base, the base having a trapezoidal cross-sectional shape.

93. A method for coupling two tubular composite structures together, comprising:

inserting a strip-tie within a first tubular composite structure and a second tubular composite structure, the strip-tie having a plurality of locking inserts predetermined distance apart from each other, wherein each of the locking inserts is adapted to receive a fastener;

aligning at least one fastener to any one of the plurality of locking inserts in the first tubular composite structure;

aligning at least one fastener to any one of the plurality of locking inserts in the second tubular composite structure;

inserting the at least one fastener through each of the first and second tubular composite structures; and

tightening the at least one fastener against each of locking inserts in the first and second tubular composite structures to couple the two tubular composite structures together.

94. A method according to claim 93, wherein the first and second tubular composite structures define a front and back fuselages of an airplane, respectively, both of the front and back fuselages formed from a plurality of triangular cross-section filament wound tubes nested complementally together in juxtaposition and arranged to cooperate together generally forming a circular cross-section, wherein the plurality of triangular cross-section filament wound tubes in the front fuselage substantially align with the plurality of triangular cross-section filament wound tubes in the back fuselage.

95. A method according to claim 94, further comprising:

inserting a predetermined number of the strip-ties between the aligned plurality of triangular cross-section filament wound tubes that make up the front and back fuselages, respectively; and

tightening at least one fastener on each side of the front and back fuselages against the corresponding locking insert on each of the predetermined number of the strip-ties to couple the front and back fuselages together.

96. A method for producing a strip-tie to couple two structures made of composite structures together, comprising:

forming a tubular member made from filament wound fibers;

placing the tubular member within a press, the press having an upper jaw and a lower jaw, wherein a cavity is formed between the upper and lower jaws when they are closed;

compressing the upper jaw relative to the lower jaw, whereby the tubular member is substantially conforms to the shape of the cavity between the upper and lower jaws; and

coupling a plurality of inserts to the conformed tubular member, wherein each of the inserts are a predetermined distances apart from each other.

97. A method according to claim 96, wherein the tubular member is wounded in a controlled direction substantially depending on the stress applied to the tubular member.

98. A method according to claim 96, wherein the upper jaw has beveled lips.

99. A method according to claim 96, further comprising:

drilling a plurality of holes on the tubular member aligning with the plurality of inserts.

100. A mandrel for coupling and insulating a tube made of fibers, comprising:

an insulation portion having a shaved end; and

a tie portion adapted to receive the shaved end of the insulation portion.

101. A mandrel according to claim 100, wherein the insulation portion is made of foam.

102. A mandrel according to claim 100, wherein the insulation and tie portions have a triangular cross-section.

103. A mandrel according to claim 100, wherein the tie portion has a plurality of holes predetermined distance apart from each other.

104. A mandrel according to claim 100, wherein fibers are wound around the insulation portion and the tie portion to form a fiber wound tube, wherein the fiber wound tube is insulated due to the insulation portion within the fiber wound tube and is adapted to couple to another fiber wound tube via the tie portion therein.

105. A doubler, comprising:

a doubler extends between a first and second fuselages, wherein the first and second fuselages are formed from a plurality of elongated co-extensive triangular cross-section filament wound tubes nested complementally together in juxtaposition and arranged to cooperate together in forming a hollow shell, wherein the doubler is coupled to the first and second fuselages to strengthen the joint area between the two fuselages.

106. A doubler according to claim 105, wherein the doubler is shaped like a ring.

107. A doubler according to claim 105, wherein the doubler is within the first and second fuselages.

108. A doubler according to claim 105, wherein the first fuselage is a front fuselage and the second fuselage is a back fuselage.

109. A method for forming a window within a fuselage, comprising:

cutting a window opening in a predetermined location on a fuselage formed from a plurality of elongated triangular filament wound tubes nested complementarily together in juxtaposition and arranged to cooperate together in substantially forming a hollow shell, wherein the window opening defines a predetermined number of cut out triangular filament wound tubes on a left side and a right side of the window opening, the window opening further defining a top side and a bottom side;

coupling a left window frame to the left side of the window opening, wherein the left window frame has a corresponding predetermined number of plugs adapted to insert into the predetermined number of cut out triangular filament wound tubes on the left side of the window opening;

coupling a right window frame to the right side of the window opening, wherein the right window frame has a corresponding predetermined number of plugs adapted to insert into the predetermined number of cut out triangular filament wound tubes on the right side of the window opening;

coupling an upper window opening to the top side of the window opening; and

coupling a lower window opening to the bottom side of the window opening.

110. A method according to clam 109, further comprising:

fastening the corresponding predetermined number of plugs on the left and right window frames to the predetermined number of cut out triangular filament wound tubes.

111. A method according to clam 109, further comprising:

bonding the corresponding predetermined number of plugs on the left and right window frames to the predetermined number of cut out triangular filament wound tubes.

112. A method according to clam 109, further comprising:

sealing the left window frame, the right window frame, the upper window frame, and the lower window frame to the window opening.

113. A method for providing a cover for a window in a fuselage of an airplane, comprising:

coupling a pair of rails along a longitudinal axis of a fuselage, wherein a window is between the pair of rails; and

sliding a cover within the pair of rails along the longitudinal axis of the fuselage, wherein the cover substantially covers the window.

114. A method according to claim 113, further comprising:

stopping the cover when the cover is substantially juxtaposed to the window.

115. A method according to claim 113, wherein the pair of rails runs across a plurality of the windows arranged longitudinally along the fuselage, wherein a corresponding cover is provided for each of the plurality of windows to slide between a first position and a second position, wherein in the first position the cover substantially covers the window and in the second position the cover is adjacent to the window.

116. A wing tie for coupling a left wing and a right wing together and inspecting therein, comprising:

a base having a base opening;

a left side adapted to couple to a mating surface of a left wing, wherein the left side has a left side opening; and

a right side adapted to couple to a mating surface of a right wing, wherein the right side has a right side opening, whereby an operator can inspect the left and right wings through the base, left, and right openings.

117. A wing tie according to claim 116, wherein the wing tie has three sides, the base and the left and right sides to substantially define a triangular shape cross-section.

118. A wing tie according to claim 116, wherein the left and right sides converge to define a tip, the mating surfaces for the left and right wings having a top side and a bottom side, wherein the top side of the left and right wings are coupled to each other along the tip of the wing tie.

119. A wing tie according to claim 118, wherein the left and right wings are formed from a plurality of elongated triangular filament wound tubes nested complementally together in juxtaposition and arranged to cooperate together in forming a wing, wherein predetermined number of triangular filament wound tubes have a plug therein, wherein each plug has a step-tab adapted to couple across the top surface of the other wing.

120. A wing tie according to claim 119, wherein the plug has a predetermined width, wherein the step-tab is about one-half the width of the plug so that the step-tab from the left wing may lay adjacent to the step-tab of the corresponding plug in the right wing.

121. A system for coupling a bulkhead to a fuselage, comprising:

a bulkhead formed from a plurality of curved triangular filament wound tubes nested complementally together in juxtaposition and arranged to cooperate together in substantially forming a concave shell;

a fuselage formed from a plurality of elongated triangular filament wound tubes nested complementally together in juxtaposition and arranged to cooperate together in substantially forming a cylindrical shell; and

a predetermined number of plugs having a curved portion substantially adapted to insert into the curved triangular filament wound tubes in the bulkhead and a substantially a straight portion adapted to insert into the elongated triangular filament wound tubes in the fuselage, wherein the plug is adapted to couple to the triangular filament wound tubes in the bulkhead and the fuselage.

122. A system according to claim 121, wherein the bulkhead and the fuselage have an outer surface, wherein each plug on the bulkhead has a step-tab adapted to couple across the top surface of the fuselage, and each plug on the fuselage has a step-tab adapted to couple across the top surface of the bulkhead.