METHODS AND SYSTEMS FOR COMPOSITE STRUCTURAL TRUSS

• US 20080245927A1
• Filed: 04/05/2007
• Published: 10/09/2008
• Est. Priority Date: 04/05/2007
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kulesha, Richard L.
• Granted Patent: US 7,954,763 B2
• Time in Patent Office: Days
• US Class Current: 244/123.1
• CPC Class Codes: B64C 3/187 Ribs

Abstract

Methods and structures for a composite truss structure are provided. The structure includes an upper chord member, a lower chord member, and a plurality of web members extending therebetween. Each of the upper chord member, the lower chord member, and the plurality of web members are formed of a continuous composite fiber positioned in each of the upper chord member, the lower chord member, and each of the plurality of web members wherein each of the upper chord member, the lower chord member, and the plurality of web members includes a predetermined number of passes of the continuous composite fiber corresponding to a predetermined load. The composite truss structure also includes at least a first gusseting plate coupled to the upper chord member, the lower chord member, and the plurality of web members.

Claims

1. A composite truss structure comprising:

an upper chord member;

a lower chord member;

a plurality of web members extending therebetween, each of said upper chord member, said lower chord member, and said plurality of web members are formed of a continuous composite fiber positioned in each of said upper chord member, said lower chord member, and each of said plurality of web members, each of said upper chord member, said lower chord member, and said plurality of web members comprising a predetermined number of passes of said continuous composite fiber corresponding to a predetermined load; and

at least a first gusseting plate coupled to said upper chord member, said lower chord member, and said plurality of web members.

2. A structure in accordance with claim 1 further comprising a second gusseting plate coupled to a side of said upper chord member, said lower chord member, and said plurality of web members opposite from said first gusseting plate wherein said first gusseting plate and said second gusseting plate sandwich said upper chord member, said lower chord member, and said plurality of web members therebetween.

3. A structure in accordance with claim 1 wherein said at least a first gusseting plate comprises a flange extending away from an edge of the respective gusseting plate.

4. A structure in accordance with claim 1 wherein the number of passes of fiber through each member is determined based on a load to be applied to said member.

5. A structure in accordance with claim 1 wherein the number of passes of fiber through a member determines a load bearing capability of the member.

6. A structure in accordance with claim 1 wherein a profile of at least one of said plates is complementary to a profile of said upper chord member, said lower chord member, and said plurality of web members.

7. A structure in accordance with claim 1 wherein said at least a first gusseting plate is routed to conform a profile of the at least a first gusseting plate and a second gusseting plate with a profile of at least one of said upper chord member, said lower chord member, and said plurality of web members.

8. A structure in accordance with claim 1 wherein said plurality of web members comprise at least one of a vertical web member, a horizontal web member, and a diagonal web member.

9. A structure in accordance with claim 1 wherein at least one of said upper chord member, said lower chord member, and said plurality of web members comprises at least one of an epoxy impregnated carbon filament, an epoxy impregnated carbon tow, and an epoxy impregnated carbon web.

10. A structure in accordance with claim 1 wherein a first end of said upper chord member is coupled to a first end of said lower chord member and a second end of said upper chord member is coupled to a second end of said lower chord member.

11. A structure in accordance with claim 1 wherein a first portion of said structure is formed separately from a second portion of said structure, the first and second portions coupled to each other to form said structure.

12. A method of forming a composite structural member comprising:

forming a profile of the structural member wherein the profile includes a channel representing interconnected structural elements;

winding a continuous fiber through the channel a predetermined number of passes through each structural element based on a strength requirement of each respective structural element; and

coupling at least one gusseting plate to said interconnected structural elements.

13. A method in accordance with claim 12 further comprising coupling a second gusseting plate to a side of said interconnected structural elements opposite from said at least one gusseting plate.

14. A method in accordance with claim 12 wherein forming a profile of the structural member comprises forming a profile that includes channels representing at least one of a vertical web member, a horizontal web member, and a diagonal web member.

15. A method in accordance with claim 12 wherein winding a continuous fiber through the channel comprises winding at least one of an epoxy impregnated carbon filament, an epoxy impregnated carbon tow, and an epoxy impregnated carbon web through the channel to form the structural elements.

16. A method in accordance with claim 12 wherein coupling at least one gusseting plate to said interconnected structural elements comprises coupling at least one gusseting plate that includes a flange extending away from an edge of a respective one of the at least one gusseting plate.

17. A method in accordance with claim 12 wherein coupling at least one gusseting plate to said interconnected structural elements comprises coupling at least one gusseting plate having a profile that is substantially complementary to a profile of the interconnected structural elements.

18. A method in accordance with claim 12 wherein forming a profile of the structural member comprises forming a profile of the structural member that includes a channel representing an upper chord member and a lower chord member wherein a first end of the upper chord member is coupled to a first end of the lower chord member and a second end of the upper chord member is coupled to a second end of the lower chord member.

19. A method in accordance with claim 12 wherein forming a profile of the structural member comprises forming a plurality of profiles of separate portions of the structural member, said method further comprising coupling each separate portion to another separate to form the structural member.

20. A method of forming an aircraft wing including a composite wing rib, said method comprising:

forming a wing rib including a plurality of interconnected structural elements using a continuous epoxy impregnated fiber positioned a predetermined number of passes in each structural element, the number of passes based on a strength requirement of each respective structural element;

coupling a gusseting plate to a side of said interconnected structural elements;

assembling at least one wing rib to a forward spar and an aft spar;

assembling a trailing edge skin to the spar and wing rib assembly;

assembling an upper and a lower center skin to the rib, spar and trailing edge skin assembly such that the center skins overlap the trailing edge skin; and

attaching the leading edge skin to the wing assembly such that the leading edge skin overlaps the center skin and trailing edge skin assembly.