JOINTS BETWEEN A COMPOSITE SKIN AND A LOAD-BEARING COMPONENT AND METHODS OF FORMING SAME

• US 20150203185A1
• Filed: 01/22/2014
• Published: 07/23/2015
• Est. Priority Date: 01/22/2014
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Rosman, Richard R., Dopker, Bernhard, Chan, Wallace Chi-Hua
• Granted Patent: US 9,399,507 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B29C 65/562 using extra joining elements, i.e. which are not integral with the parts to be joined using plastic snap elements B29C65/58; using plastic rivets B29C65/601
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/21 said joint lines being formed by a single dot or dash or by several dots or dashes, i.e. spot joining or spot welding
• CPC Class Codes: B29C 66/532 Joining single elements to the wall of tubular articles, hollow articles or bars
• 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 66/7392 characterised by the material of at least one of the parts being a thermoplastic
• CPC Class Codes: B29C 66/7394 characterised by the material of at least one of the parts being a thermoset
• CPC Class Codes: B29K 2105/08 of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
• CPC Class Codes: B29K 2307/04 Carbon
• CPC Class Codes: B29L 2031/3082 Fuselages
• CPC Class Codes: B64C 1/12 Construction or attachment of skin panels
• CPC Class Codes: B64C 2001/0072 from composite materials
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 29/49696 Mounting
• CPC Class Codes: Y10T 403/70 Interfitted members
• CPC Class Codes: Y10T 403/7075 including discrete retainer

Abstract

A method of forming a direct bearing joint includes providing a load bearing structure including a first structural feature having an arcuate shape and providing a composite skin including a second structural feature also having an arcuate shape. The method also includes coupling the first structural feature to the second structural feature such that the first and second structural features are mated against each other to facilitate distributing compressive loads induced into the load bearing structure into the composite skin.

Claims

1. A method of forming a direct bearing joint, said method comprising:

providing a load bearing structure including a first structural feature having an arcuate shape;

providing a composite skin including a second structural feature having an arcuate shape; and

coupling the first structural feature to the second structural feature such that the first and second structural features are mated against each other to facilitate distributing compressive loads induced into the load bearing structure into the composite skin.

2. The method in accordance with claim 1, wherein providing a load bearing structure including a first structural feature further comprises providing a load bearing structure including a convex platform edge, and wherein providing a composite skin including a first structural feature further comprises providing a composite skin including a concave cutout edge.

3. The method in accordance with claim 2, wherein coupling the first structural feature to the second structural feature further comprises mating the convex platform edge in continuous direct contact against the concave cutout edge.

4. The method in accordance with claim 1, further comprising coupling the load bearing structure to the composite skin using a plurality of fasteners such that a first load path is defined through the first and second structural features and a second load path is defined through the plurality of fasteners.

5. The method in accordance with claim 1, wherein providing a load bearing structure further comprises providing one of a wheel well longeron, a keel beam, and a wing rear spar frame of an aircraft.

6. The method in accordance with claim 1, wherein providing a load bearing structure further comprises providing a bearing plate that is coupled to an airframe component selected from a group consisting of a wheel well longeron, a keel beam, and a wing rear spar frame of an aircraft.

7. The method in accordance with claim 1, wherein the load bearing structure includes a structural flange, the method further comprising coupling the composite skin between the structural flange and a bulkhead.

8. The method in accordance with claim 7 further comprising:

coupling a first inner surface of the second structural feature in a face-to-face relationship with an outer surface of the bulkhead; and

coupling a second inner surface of the composite skin in a face-to-face relationship with the outer surface such that the first and second inner surfaces are flush.

9. A direct bearing joint comprising:

a load bearing structure comprising a first structural feature that has an arcuate shape; and

a composite skin coupled to said load bearing structure, said composite skin comprising a second structural feature that has an arcuate shape, said second structural feature configured to mate against said first structural feature to facilitate distributing compressive loads induced into said load bearing structure into said composite skin.

10. The joint in accordance with claim 9, wherein said first structural feature is a convex platform and said second structural feature is a complementary concave cutout.

11. The joint in accordance with claim 9, wherein said first structural feature comprises a first edge, said second structural feature comprises a second edge that is shaped to mate against said first edge.

12. The joint in accordance with claim 9, wherein said load bearing structure is one of a wheel well longeron, a keel beam, and a wing rear spar frame of an aircraft.

13. The joint in accordance with claim 9, further comprising a plurality of fasteners configured to couple said composite skin to said load bearing structure, such that a first load path is defined through said first and second structural features, and a second load path is defined through said plurality of fasteners.

14. The joint in accordance with claim 9, wherein said load bearing structure is a bearing plate coupled to one of a wheel well longeron, a keel beam, and a wing rear spar frame of an aircraft.

15. The joint in accordance with claim 9, further comprising a bulkhead, said load bearing structure further comprises an extension flange, said composite skin is coupled between said extension flange and said bulkhead.

16. The joint in accordance with claim 15, wherein said second arcuate feature comprises a first inner surface coupled in a mating relationship with an outer surface of said bulkhead, said composite skin comprises a second inner surface coupled in a mating relationship with said outer surface of said bulkhead such that said first and second inner surfaces are substantially flush against each other.

17. An aircraft comprising a direct bearing joint, said aircraft comprising:

a load bearing structure comprising a first structural feature that has an arcuate shape;

a composite skin coupled to said load bearing structure, said composite skin comprising a second structural feature that has an arcuate shape, said second structural feature configured to mate against said first structural feature to facilitate distributing compressive loads induced into said load bearing structure into said composite skin.

18. The aircraft in accordance with claim 17, wherein said first structural feature comprises a first edge, said second structural feature comprises a second edge that is shaped to mate against said first edge.

19. The aircraft in accordance with claim 17, wherein said load bearing structure is one of a wheel well longeron, a keel beam, and a wing rear spar frame.

20. The aircraft in accordance with claim 17 further comprising a plurality of fasteners configured to couple said composite skin to said load bearing structure, such that a first load path is defined through said first and second structural features, and a second load path is defined through said plurality of fasteners.