Multi-functional aircraft structures

• US 8,617,687 B2
• Filed: 08/03/2009
• Issued: 12/31/2013
• Est. Priority Date: 08/03/2009
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: McCarville, Douglas A., Guzman, Juan C., Rotter, Daniel M.
• Primary Examiner(s): Shosho, Callie
• Assistant Examiner(s): Jordan, Nicholas W
• Application Number:
  US12/534,356
• Publication Number:
  US 20110027526A1
• Time in Patent Office: 1,611 Days
• Field of Search: 428/116, 428/158, 428/167, 428/117, 428/608, 244/123.1, 24412312-12314, 244/123.3, 244/123.5, 244/123.6, 244/123.8, 244/123.9, 244/128, 385/125, 156/293, 156/294
• US Class Current: 428/117
• 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 structure comprising:

a composite structure configured for use in or on an aircraft, the composite structure selected from the group consisting of;

a stringer of the aircraft, a floor panel of the aircraft, a cryogenic tank installed on the aircraft, a spar of the aircraft, and a rib of the aircraft;

a filler material disposed within and abutting all first inner walls of the composite structure;

a first barrier material secured to second inner walls of the filler material, the second inner walls being further within the composite structure relative to the first inner walls, and third inner walls of the first barrier material defining a first channel inside the composite structure; and

a second barrier material secured to fourth inner walls of the filler material, the fourth inner walls being further within the composite structure relative to the first inner walls, and fifth inner walls of the second barrier material defining a second channel inside the composite structure;

wherein 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 is located in one of the first channel and the second channel.

2. The structure of claim 1 further comprising:

a number of additional sets of inner walls within the filler material; and

corresponding additional sets of barrier materials being secured to corresponding ones of each of the additional sets of inner walls, wherein corresponding additional channels are defined within the corresponding additional sets of barrier materials.

3. The structure of claim 1, wherein the other of the first channel and the second channel forms a waveguide.

4. The structure of claim 1, wherein the other of the first channel and the second channel is configured to receive a liquid, air, or a gas.

5. The structure of claim 1, wherein the first and second barrier materials are selected from the group consisting of a metal, copper, aluminum, titanium, a plastic, and polyvinyl chloride.

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

7. The structure of claim 1, wherein the other of the first channel and the second channel is part of a system selected from the group consisting of an air duct and a fire suppression system.

8. The structure of claim 1, wherein the composite structure comprises the stringer and wherein the composite structure is further configured for both stiffening the aircraft and media transport within the stringer.

9. The structure of claim 1, wherein the filler material further separates the first channel from the second channel.

10. The structure of claim 1, wherein the composite structure comprises a trapezoid shape, and wherein the first barrier material, the second barrier material, and the filler material form an I-beam and sides configuration.

11. A structure comprising:

a composite structure configured for use in or on an aircraft, the composite structure selected from the group consisting of;

a stringer of the aircraft, a floor panel of the aircraft, a cryogenic tank installed on the aircraft, a spar of the aircraft, and a rib of the aircraft, wherein the composite structure has a first trapezoid shape;

a filler material disposed within and abutting all first inner walls of the composite structure, wherein the filler material has a second trapezoid shape; and

a barrier material secured to second inner walls of the filler material, the second inner walls being further within the composite structure relative to the first inner walls, and third inner walls of the barrier material defining a first channel inside the composite structure, wherein the barrier material has a third trapezoid shape;

wherein 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 is located in the first channel.

12. A structure comprising:

a composite structure configured for use in or on an aircraft, the composite structure selected from the group consisting of;

a stringer of the aircraft, a floor panel of the aircraft, a cryogenic tank installed on the aircraft, a spar of the aircraft, and a rib of the aircraft, the composite structure having disposed therein a filler material and a barrier material, a channel being defined inside the barrier material, the filler material disposed only on one side of the barrier material, the filler material abutting the barrier material and outside the channel, wherein 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 is located in the channel.

13. The structure of claim 12, wherein the barrier material and the channel are configured to receive air, or a gas.

14. The structure of claim 12, wherein the barrier material is selected from the group consisting of a metal, copper, aluminum, titanium, a plastic, and polyvinyl chloride, and wherein the filler material is selected from the group consisting of a foam, fiberglass, a honeycomb structure, a vibration reduction material, an insulation material, and wood.

15. The structure of claim 12 wherein the barrier material and the filler material form a top foam configuration.

16. The structure of claim 12, wherein the channel and the barrier material are part of a system selected from the group consisting of an air duct and a fire suppression system.