Structural panels for use in aircraft fuselages and other structures

• US 7,134,629 B2
• Filed: 05/25/2004
• Issued: 11/14/2006
• 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.
• Primary Examiner(s): Carone, Michael J.
• Assistant Examiner(s): Radi, John A
• Application Number:
  US10/853,075
• Publication Number:
  US 20050263645A1
• Time in Patent Office: 903 Days
• Field of Search: 52664-667, 527/961.2, 527/971, 521/981, 527/991.3, 244/117.R, 244/119, 244/123.12, 244/124, 244/129.1, 244131-133
• 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, wherein the first flange portion has a first outer edge;

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 the second flange portion has a second outer edge facing the first outer edge, and 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 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 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.

3. The structural panel of claim 1 wherein the first outer edge is spaced apart from the second outer edge by a distance of about 0.5 inch or less.

4. The structural panel of claim 1 wherein the first outer edge is spaced apart from the second outer edge by a distance of about 0.2 inch or less.

5. The structural panel of claim 1 wherein the first outer edge is spaced apart from the second outer edge by a distance of about 0.1 inch or less.

6. 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.

7. 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.

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, the second frame section having a C-shaped cross-section.

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

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

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

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

19. The structural panel of claim 1 wherein the base portion of the support member is mated to the 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.

13. 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, wherein the first flange portion has a first outer edge;

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 the second flange portion has a second outer edge facing the first outer edge, and 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 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.

14. The aircraft fuselage of claim 13 wherein the plurality of structural panels are operably coupled together to form an exterior portion of the passenger cabin.

15. The aircraft fuselage of claim 13 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.

16. The aircraft fuselage of claim 13, further comprising a plurality of passenger seats positioned in the passenger cabin ranging in number from about 50 seats to about 700 seats.

17. The aircraft fuselage of claim 13, 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.

18. The aircraft fuselage of claim 13 wherein the plurality of structural panels are operably coupled together to form a floor of the passenger cabin.

20. The aircraft fuselage of claim 13 wherein the base portion of the frame section is mated to the 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.