Multi-Functional Aircraft Structures

• US 20110027526A1
• Filed: 08/03/2009
• Published: 02/03/2011
• Est. Priority Date: 08/03/2009
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Rotter, Daniel M., McCarville, Douglas A., Guzman, Juan C.
• Granted Patent: US 8,617,687 B2
• Time in Patent Office: Days
• US Class Current: 428/116
• CPC Class Codes: B29C 70/302 Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
• CPC Class Codes: B29C 70/865 completely encapsulated
• CPC Class Codes: B29D 99/001 Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings articles with hollow walls B29D24/00
• CPC Class Codes: B29D 99/0017 with filled hollow ridges
• CPC Class Codes: B29L 2031/3076 Aircrafts blades, propellers B29L2031/08
• CPC Class Codes: B64C 1/061 Frames
• CPC Class Codes: B64C 1/064 Stringers; Longerons
• CPC Class Codes: B64C 1/065 Spars
• CPC Class Codes: B64C 1/18 Floors
• CPC Class Codes: B64C 2001/0072 from composite materials
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 428/24149 Honeycomb-like
• CPC Class Codes: Y10T 428/24157 Filled honeycomb cells [e.g., solid substance in cavities, etc.]
• CPC Class Codes: Y10T 428/24496 Foamed or cellular component
• CPC Class Codes: Y10T 428/2457 Parallel ribs and/or grooves

Abstract

A method and apparatus for manufacturing a composite structure. A filler material with a barrier material for a channel in the filler material is formed. A composite material and the filler material with the barrier material are laid up onto a tool in a shape of the composite structure. The composite material and the filler material in the shape of the composite structure are cured.

Claims

1. A method for manufacturing a composite structure, the method comprising:

forming a filler material with a barrier material for a channel in the filler material;

laying up a composite material and the filler material with the barrier material onto a tool in a shape of the composite structure; and

curing the composite material and the filler material in the shape of the composite structure.

2. The method of claim 1, wherein the forming step comprises:

forming the filler material with the barrier material for the channel in a foam with a mandrel in the channel.

3. The method of claim 2 further comprising:

removing the mandrel from the filler material to form the composite structure, wherein the barrier material forms a barrier for a channel in the composite structure.

4. The method of claim 1, wherein the filler material is a foam, and wherein the laying up step comprises:

laying up the composite material onto an inside mold line; and

placing the foam with the barrier material and a mandrel onto the composite material.

5. The method of claim 4, wherein the laying up step further comprises:

placing a skin ply over the foam and the composite material.

6. The method of claim 1, wherein the filler material is a foam and wherein the laying up step comprises:

placing the foam onto a skin ply; and

placing the composite material over the foam.

7. The method of claim 6, wherein the laying up step is performed using an outside mold line.

8. The method of claim 1, wherein the step of forming the filler material with the barrier material for the channel in the filler material comprises:

forming the filler material with the barrier material for the channel in the filler material and for a number of channels in addition to the channel in the filler material.

9. The method of claim 1, wherein the barrier material and the channel form a waveguide.

10. The method of claim 1, wherein the channel includes at least one of a number of fiber optic cables, a number of power lines, a number of wires, and a number of data lines.

11. The method of claim 1, wherein the barrier material and the channel are configured to receive a liquid, air, or a gas.

12. The method of claim 1, wherein the barrier material is selected from a group consisting of a metal, copper, aluminum, titanium, a plastic, and polyvinyl chloride.

13. The method of claim 1, wherein the filler material is selected from a group consisting of a foam, fiberglass, a honeycomb structure, a vibration-reduction material, an insulation material, and wood.

14. The method of claim 1, wherein the composite structure is selected from a group consisting of a stringer, a frame, a floor panel, a cryogenic tank, a dry inter-stage structure, a spar, and a rib.

15. The method of claim 1, wherein the channel and the barrier material are part of a system selected from a group consisting of an air duct, a fire suppression system, and a waveguide.

16. The method of claim 1, wherein the composite structure is for a vehicle selected from a group consisting of an aircraft and a spacecraft.

17. An apparatus comprising:

a composite structure having a first channel;

a filler material located in the first channel; and

a barrier material associated with walls of a second channel in the filler material.

18. The apparatus of claim 17 further comprising:

a number of channels in addition to the second channel in the filler material, wherein the barrier material covers the walls of the number of channels.

19. The apparatus of claim 17, wherein the barrier material is a first barrier material and further comprising:

a number of channels in addition to the second channel in the filler material; and

a second barrier material, wherein the second barrier material covers the walls of the number of channels.

20. The apparatus of claim 17, wherein the barrier material and the channel form a waveguide.

21. The apparatus of claim 17 further comprising:

at least one of a number of fiber optic cables, a number of power lines, a number of wires, and a number of data lines located in the channel.

22. The apparatus of claim 17, wherein the barrier material and the second channel are configured to receive a liquid, air, or a gas.

23. The apparatus of claim 17, wherein the barrier material is selected from a group consisting of a metal, copper, aluminum, titanium, a plastic, and polyvinyl chloride.

24. The apparatus of claim 17, wherein the filler material is selected from a group consisting of a foam, fiberglass, a honeycomb structure, a vibration reduction material, an insulation material, and wood.

25. The apparatus of claim 17, wherein the composite structure is selected from a group consisting of a stringer, a frame, a floor panel, a cryogenic tank, a dry inter-stage structure, a spar, and a rib.

26. The apparatus of claim 17, wherein the channel and the barrier material are part of a system selected from a group consisting of an air duct, a fire suppression system, and a waveguide.

27. The apparatus of claim 17, wherein the composite structure is for a vehicle selected from a group consisting of an aircraft and a spacecraft.

28. An apparatus comprising:

a composite structure having a channel; and

a barrier material associated with walls of the channel.

29. The apparatus of claim 28, wherein the channel is a first channel and further comprising:

a filler material located in the first channel, wherein the filler material has a second channel and the barrier material is associated with the walls of the second channel.

30. The apparatus of claim 28 further comprising:

a filler material, wherein the filler material defines at least a portion of the walls of the channel.

31. The apparatus of claim 28, wherein the walls of the channel comprise a composite material in the composite structure.