Structural panels for use in aircraft fuselages and other structures

• US 20050263645A1
• Filed: 05/25/2004
• Published: 12/01/2005
• Est. Priority Date: 04/06/2004
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Johnson, Kent, Ulvin, Mark A.
• Granted Patent: US 7,134,629 B2
• Time in Patent Office: Days
• US Class Current: 244/119
• CPC Class Codes: B61D 17/041 with bodies characterised by use of light metal, e.g. aluminium B61D17/045 takes precedence
• CPC Class Codes: B63B 3/28 of transverse type; Stringers
• CPC Class Codes: B63B 3/36 Combined frame systems
• CPC Class Codes: B64C 1/12 Construction or attachment of skin panels
• CPC Class Codes: B64C 2001/0072 from composite materials
• CPC Class Codes: B64C 2001/0081 from metallic materials
• CPC Class Codes: B64C 3/182 Stringers, longerons
• CPC Class Codes: B64C 3/26 Construction, shape, or attachment of separate skins, e.g. panels
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 156/1089 of discrete laminae to single face of additional lamina
• CPC Class Codes: Y10T 29/49616 Structural member making
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/53978 including means to relatively position plural work parts
• CPC Class Codes: Y10T 428/24033 including stitching and discrete fastener[s], coating or bond
• CPC Class Codes: Y10T 428/24174 including sheet or component perpendicular to plane of web or sheet
• CPC Class Codes: Y10T 428/24182 Inward from edge of web or sheet
• CPC Class Codes: Y10T 428/24198 Channel-shaped edge component [e.g., binding, etc.]

Abstract

Structural panels for use in manufacturing aircraft fuselages and other structures are disclosed herein. In one embodiment, a structural panel configured in accordance with the invention includes a skin and at least first and second stiffeners. The first stiffener can have a first flange portion mated to the skin and a first raised portion projecting away from the skin. The second stiffener can have a second flange portion mated to the skin and a second raised portion projecting away from the skin. At least one of the first flange portion of the first stiffener and the second flange portion of the second stiffener can extend toward the other of the first flange portion and the second flange portion to form an at least approximately continuous support surface to which a frame can be attached.

Claims

1. A structural panel comprising:

a skin;

a first stiffener having a first flange portion mated to the skin and a first raised portion projecting away from the skin;

at least a second stiffener spaced apart from the first stiffener, the second stiffener having a second flange portion mated to the skin and a second raised portion projecting away from the skin; and

a support member having a base portion mated to the first flange portion of the first stiffener and the second flange portion of the second stiffener without being mated to the skin between the first raised portion of the first stiffener and the second raised portion of the second stiffener.

2. The structural panel of claim 1 wherein at least one of the first flange portion of the first stiffener and the second flange portion of the second stiffener extends toward the other to form an at least approximately continuous support surface extending between the first raised portion of the first stiffener and the second raised portion of the second stiffener.

3. The structural panel of claim 1 wherein the base portion of the support member includes a mating surface absent a joggle, and wherein the mating surface contacts the first flange portion of the first stiffener and the second flange portion of the second stiffener.

4. The structural panel of claim 1 wherein the first flange portion of the first stiffener has a first outer edge and the second flange portion of the second stiffener has a second outer edge facing the first outer edge, and wherein the first outer edge is spaced apart from the second outer edge by a distance of about 0.5 inch or less.

5. The structural panel of claim 1 wherein the first flange portion of the first stiffener has a first outer edge and the second flange portion of the second stiffener has a second outer edge facing the first outer edge, and wherein the first outer edge is spaced apart from the second outer edge by a distance of about 0.2 inch or less.

6. The structural panel of claim 1 wherein the first flange portion of the first stiffener has a first outer edge and the second flange portion of the second stiffener has a second outer edge facing the first outer edge, and wherein the first outer edge is spaced apart from the second outer edge by a distance of about 0.1 inch or less.

7. The structural panel of claim 1 wherein the support member further includes at least first and second openings, and wherein the first raised portion of the first stiffener extends through the first opening and the second raised portion of the second stiffener extends through the second opening.

8. The structural panel of claim 1 wherein the support member is a first frame section that further includes an upstanding portion projecting away from the base portion, and wherein the structural panel further includes a second frame section attached to the upstanding portion of the first frame section.

9. The structural panel of claim 1 wherein the support member is a first frame section that further includes an upstanding portion projecting away from the base portion, and wherein the structural panel further includes a second frame section attached to the upstanding portion of the first frame section, the second frame section having a C-shaped cross-section.

10. The structural panel of claim 1 wherein the first and second stiffeners are at least approximately identical.

11. The structural panel of claim 1 wherein the first and second stiffeners have hat-shaped cross-sections.

12. The structural panel of claim 1 wherein the first and second stiffeners are adhesively bonded to the skin.

13. The structural panel of claim 1 wherein at least the skin and the first and second stiffeners include a composite material.

14. A structural panel comprising:

a skin;

a first stiffener having a first flange portion mated to the skin and a first raised portion projecting away from the skin;

at least a second stiffener spaced apart from the first stiffener, the second stiffener having a second flange portion mated to the skin and a second raised portion projecting away from the skin, wherein at least one of the first flange portion of the first stiffener and the second flange portion of the second stiffener extends toward the other to form an at least approximately continuous support surface extending between the first raised portion of the first stiffener and the second raised portion of the second stiffener; and

a support member in contact with the support surface between the first raised portion of the first stiffener and the second raised portion of the second stiffener.

15. The structural panel of claim 14 wherein the support member includes at least first and second openings, and wherein the first raised portion of the first stiffener extends through the first opening and the second raised portion of the second stiffener extends through the second opening.

16. The structural panel of claim 14 wherein the support member includes at least first and second openings and a mating surface, wherein the first raised portion of the first stiffener extends through the first opening and the second raised portion of the second stiffener extends through the second opening, wherein the mating surface extends from the first opening to the second opening in the absence of a joggle, and wherein the mating surface contacts the support surface between the first raised portion of the first stiffener and the second raised portion of the second stiffener.

17. The structural panel of claim 14 wherein the first flange portion of the first stiffener has a first outer edge and the second flange portion of the second stiffener has a second outer edge facing the first outer edge, and wherein the first outer edge is spaced apart from the second outer edge by a distance of about 0.2 inch or less.

18. The structural panel of claim 14 wherein the first flange portion of the first stiffener has a first outer edge and the second flange portion of the second stiffener has a second outer edge facing the first outer edge, and wherein the first outer edge is spaced apart from the second outer edge by a distance of about 0.1 inch or less.

19. The structural panel of claim 14 wherein the support member is attached to the first and second stiffeners.

20. An aircraft fuselage comprising:

a passenger cabin; and

a plurality of structural panels operably coupled together to form a portion of the passenger cabin, wherein each of the structural panels includes;

a skin;

a first stiffener having a first flange portion mated to the skin and a first raised portion projecting away from the skin;

at least a second stiffener spaced apart from the first stiffener, the second stiffener having a second flange portion mated to the skin and a second raised portion projecting away from the skin; and

a frame section having a base portion mated to the first flange portion of the first stiffener and the second flange portion of the second stiffener without being mated to the skin between the first raised portion of the first stiffener and the second raised portion of the second stiffener.

21. The aircraft fuselage of claim 20 wherein the plurality of structural panels are operably coupled together to form an exterior portion of the passenger cabin.

22. The aircraft fuselage of claim 20 wherein the skin includes a composite material, and wherein the plurality of structural panels are operably coupled together to form an exterior portion of the passenger cabin.

23. The aircraft fuselage of claim 20, further comprising a plurality of passenger seats positioned in the passenger cabin ranging in number from about 50 seats to about 700 seats.

24. The aircraft fuselage of claim 20, further comprising a plurality of passenger seats positioned in the passenger cabin ranging in number from about 50 seats to about 700 seats, and wherein the skin and stiffeners include composite materials.

25. The aircraft fuselage of claim 20 wherein the plurality of structural panels are operably coupled together to form a floor of the passenger cabin.

26. A method for manufacturing a structural panel, the method comprising:

mating at least a first flange portion of a first stiffener to a skin, the first stiffener further including a first raised portion projecting away from the skin;

mating at least a second flange portion of a second stiffener to the skin, the second stiffener further including a second raised portion projecting away from the skin; and

mating a base portion of a support member to the first flange portion of the first stiffener and the second flange portion of the second stiffener without mating the base portion to the skin between the first raised portion of the first stiffener and the second raised portion of the second stiffener.

27. The method of claim 26, further comprising:

positioning the first flange portion of the first stiffener at least proximate to the second flange portion of the second stiffener to form an at least approximately continuous support surface extending between the first raised portion of the first stiffener and the second raised portion of the second stiffener; and

positioning the base portion of the support member in contact with the support surface.

28. The method of claim 26, further comprising manufacturing the support member from composite materials.

29. The method of claim 26, further comprising manufacturing the skin and the first and second stiffeners from composite materials.

30. The method of claim 26 wherein mating at least a first flange portion of a first stiffener to a skin includes adhesively bonding the first flange portion of the first stiffener to the skin, and wherein mating at least a second flange portion of a second stiffener to the skin includes adhesively bonding the second flange portion of the second stiffener to the skin.

31. The method of claim 26 wherein mating at least a first flange portion of a first stiffener to a skin includes adhesively bonding the first flange portion of the first stiffener to the skin, wherein mating at least a second flange portion of a second stiffener to the skin includes adhesively bonding the second flange portion of the second stiffener to the skin, and wherein mating a base portion of a support member to the first flange portion of the first stiffener and the second flange portion of the second stiffener includes adhesively bonding the base portion to the first and second flange portions.

32. The method of claim 26 wherein mating at least a first flange portion of a first stiffener to a skin and mating at least a second flange portion of a second stiffener to the skin includes co-curing the first stiffener, the second stiffener, and the skin to bond the first and second flange portions to the skin.

33. The method of claim 26 wherein the support member is a first frame section, and wherein the method further comprises attaching a second frame section to the first frame section.

34. The method of claim 26 wherein the support member is a first frame section, and wherein the method further comprises attaching a second frame section to the first frame section after mating the base portion of the first frame section to the first flange portion of the first stiffener and the second flange portion of the second stiffener.

35. The method of claim 26 wherein the support member is a first frame section further including an upstanding portion projecting away from the base portion, and wherein the method further comprises attaching a second frame section to the upstanding portion of the first frame section.

36. The method of claim 26 wherein the support member is a first frame section further including an upstanding portion projecting away from the base portion, and wherein the method further comprises attaching a second frame section to the upstanding portion of the first frame section, the second frame section having a C-shaped cross-section.

37. A method for manufacturing a structural panel, the method comprising:

positioning a first flange portion of a first stiffener on a skin, the first stiffener further including a first raised portion projecting away from the skin;

positioning a second flange portion of a second stiffener at least proximate to the first flange portion of the first stiffener to form an at least approximately continuous support surface extending between the first raised portion of the first stiffener and the second raised portion of the second stiffener; and

mating a base portion of a support member to the at least approximately continues support surface without mating the base portion to the skin between the first raised portion of the first stiffener and the second raised portion of the second stiffener.

38. The method of claim 37, further comprising manufacturing the support member from composite materials.

39. The method of claim 37, further comprising:

positioning a first opening in the support member around the first raised potion of the first stiffener; and

positioning a second opening in the support member around the second raised portion of the second stiffener.

40. A system for carrying structural loads, the system comprising:

skin means for carrying shear loads;

first stiffener means for carrying a first portion of axial loads;

at least second stiffener means spaced apart from the first stiffener means for carrying a second portion of the axial loads;

means for mating the first and second stiffener means to the skin means;

frame means for carrying bending loads; and

means for operably coupling the frame means to the first and second stiffener means and the skin means without surface-to-surface contact between the frame means and the skin means.

41. The system of claim 40, further comprising means for allowing the first and second stiffener means to extend at least partially through the frame means.

42. The system of claim 40 wherein the means for operably coupling the frame means to the first and second stiffener means and the skin means includes means for sandwiching portions of the first and second stiffener means between the frame means and the skin means.

43. The system of claim 40 wherein the means for attaching the first and second stiffener means to the skin means includes means for bonding the first and second stiffener means to the skin means.