Method of assembling a single piece co-cured structure

• US 20050211843A1
• Filed: 12/01/2004
• Published: 09/29/2005
• Est. Priority Date: 07/30/2002
• Status: Active Grant

• Current Assignee: General Atomics Aeronautical Systems Incorporated (General Atomic Technologies Corporation)
• Original Assignee: Rocky Mountain Composites, Inc.
• Inventors: Ashton, Larry J., Simpson, Craig B., Tuttle, Steven T., Allman, Mike G.
• Granted Patent: US 7,216,832 B2
• Time in Patent Office: Days
• US Class Current: 244/119
• CPC Class Codes: B29C 70/342 using isostatic pressure
• CPC Class Codes: B29C 70/446 Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames
• CPC Class Codes: B29C 70/549 Details of caul plates, e.g. materials or shape
• CPC Class Codes: B29L 2031/3082 Fuselages
• CPC Class Codes: B29L 2031/3085 Wings
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10S 264/904 Maintaining article in fixed shape during heat-setting

Abstract

A method for manufacturing a composite structure is disclosed herein. The process uses a frame and selectively pressurizable forms. The forms define the interior members of the composite structure and frames define the exterior surface of the composite structure. Composite material is wrapped around the forms and the forms and composite material are placed in the frame. Selective forms are then pressurized and the composite material is co-cured together. A single piece co-cured fuselage incorporating a plurality of stiffeners is also disclosed in the application. The stiffeners are co-cured to the fuselage and may be in various patterns. The patterns may include an iso-grid pattern, and ortho-grid pattern, and a hoop-grid pattern.

Claims

1. A single piece co-cured fuselage comprising:

a composite fuselage structure having an interior and an exterior; and

a plurality of composite stiffeners located on the interior of the fuselage, wherein the composite stiffeners are co-cured to the fuselage.

2. The single piece co-cured fuselage, as recited in claim 1, wherein the composite stiffeners are hollow-core.

3. The single piece co-cured fuselage, as recited in claim 1, wherein tubes are located within the stiffeners.

4. The single piece co-cured fuselage, as recited in claim 3, wherein the tubes are inflatable.

5. The single piece co-cured fuselage, as recited in claim 1, wherein the composite stiffeners are in an iso-grid pattern.

6. The single piece co-cured fuselage, as recited in claim 1, wherein the composite stiffeners are in an ortho-grid pattern.

7. The single piece co-cured fuselage, as recited in claim 1, wherein the composite stiffeners are in a hoop-grid pattern.

8. The single piece co-cured fuselage, as recited in claim 1, wherein the composite stiffeners are circumferentially positioned on the interior of the fuselage.

9. The single piece co-cured fuselage, as recited in claim 1, wherein the fuselage has at least one door and at least one window.

10. The single piece co-cured fuselage, as recited in claim 9, further comprising composite stiffeners substantially positioned around the perimeter of the at least one door and the at least one window.

12. The single piece co-cured fuselage, as recited in claim 10, wherein the composite stiffeners are hollow-core.

13. The single piece co-cured fuselage, as recited in claim 10, wherein tubes are located within the stiffeners.

14. The single piece co-cured fuselage, as recited in claim 13, wherein the tubes are inflatable.

15. The single piece co-cured fuselage, as recited in claim 10, wherein the fuselage has at least one door and at least one window.

16. The single piece co-cured fuselage, as recited in claim 15, further comprising composite stiffeners substantially positioned around the perimeter of the at least one door and the at least one window.

11. A single piece co-cured fuselage comprising:

a composite fuselage structure having an interior and an exterior; and

a plurality of iso-grid composite stiffeners located on the interior of the fuselage, wherein the iso-grid composite stiffeners are diagonally oriented relative to a horizontal axis of the fuselage, and wherein the iso-grid stiffeners are co-cured to the fuselage.