Joining composite fuselage sections along window belts

• US 8,939,406 B2
• Filed: 07/02/2012
• Issued: 01/27/2015
• Est. Priority Date: 07/02/2012
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Dopker, Bernhard, Chan, Wallace Chi-Hua, Ostroff, Henri Michael
• Primary Examiner(s): Ellis, Christopher P
• Application Number:
  US13/540,005
• Publication Number:
  US 20140001311A1
• Time in Patent Office: 939 Days
• Field of Search: 244/120, 244/119, 244/129.3
• US Class Current: 244/120
• CPC Class Codes: B64C 1/00 Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
• CPC Class Codes: B64C 1/069 Joining arrangements therefor
• CPC Class Codes: B64C 2001/0072 from composite materials
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A fuselage having a longitudinal window belt has a composite outer skin including upper and lower composite skin sections. The skin includes at least one window opening located at the window belt. The upper and lower skin sections are joined together by a longitudinal splice joint located at the window belt.

Claims

1. A fuselage, comprising:

a composite skin including upper and lower composite skin sections;

a window belt in the composite skin, the window belt including at least one window opening in the composite skin; and

a longitudinal splice joint along the window belt joining the upper and lower skins sections together at the window belt.

2. The fuselage of claim 1, wherein the splice joint includes an adhesive bond between the upper and lower skin sections.

3. The fuselage of claim 2, wherein each of the upper and lower skin sections include laminated resin plies with ply drop-offs each forming bonding surfaces along the splice joint.

4. The fuselage of claim 1, wherein the upper and lower skin sections have overlapping tapered edges joined together along the splice joint.

5. The fuselage of claim 1, wherein the splice joint includes a composite splice strap bonded to each of the upper and lower skin sections.

6. The fuselage of claim 1, wherein:

the composite skin includes an area of increased thickness within the window belt, and

the splice joint is located within the area of increased thickness of the skin.

7. The fuselage of claim 6, wherein the window is located in within the area of increased thickness of the skin.

8. The fuselage of claim 1, wherein each of the upper and lower skin sections is a half barrel.

9. The fuselage of claim 1, further comprising:

first and second longitudinally extending stringers attached to the composite skin, wherein the splice joint and the window are located between the first and second stringers.

10. The fuselage of claim 1, wherein:

the splice joint has a height, and

the window has a height greater than the height of the splice joint.

11. The fuselage of claim 1, wherein the splice joint includes at least a first splice plate fastened to the upper and lower skin sections.

12. The fuselage of claim 11, wherein:

the upper and lower skin sections include inside surfaces and outside surfaces, and

the first splice plate is fastened to the upper and lower skin sections by mechanical fasteners, the first splice plate being located inside the fuselage and engaging the inside surfaces of the upper and lower skin sections.

13. The fuselage of claim 11, wherein:

the splice joint includes a second splice plate attached to the upper and lower skins sections, and

the first splice plate is an internal splice plate and the second splice plate is an external splice plate.

14. The fuselage of claim 13, wherein:

the upper and lower skin sections each include stepped edges forming a longitudinally extending recess in the upper and lower skins, and

the second splice plate is located within the recess.

15. The fuselage of claim 1, wherein the splice joint includes:

a window frame substantially surrounding the window opening and attached to the upper and lower skin sections, and

the window frame includes splice plate portions extending longitudinally along the window belt and fastened to the upper and lower skin sections.

16. The fuselage of claim 15, wherein:

the upper and lower skin sections include adjacent interior surfaces extending longitudinally along a joint line, and

the splice plate portions are attached to the adjacent inside surfaces and span the joint line.

17. The fuselage of claim 1, wherein:

the window belt includes a longitudinal centerline,

each of the upper and lower skin sections is a barrel half, and

the splice joint joins the barrel halves along a centerline of the window belt.

18. A fuselage barrel assembly, comprising:

upper and lower fuselage barrel halves respectively including upper and lower composite skin sections forming a fuselage skin;

window belts in the composite skin respectively on each side of the upper and lower fuselage barrel halves, the composite skin having an increased thickness within the window belts;

window openings in the fuselage skin along each of the window belts; and

splice joints between joining the upper and lower skin sections respectively extending longitudinally along at the window belts.

19. The fuselage barrel assembly of claim 18, wherein:

the upper and lower composite skin sections include tapered overlapping edges, and

each of the splice joints includes a bond between the tapered overlapping edges.

20. The fuselage barrel assembly of claim 19, wherein each of the tapered overlapping edges includes fiber reinforced composite resin ply steps forming bonding surfaces.

21. The fuselage barrel assembly of claim 18, wherein:

the upper and lower composite skin sections include tapered edges along the splice joints, and

each of the splice joints includes a tapered splice strap bonded to the tapered edges of the upper and lower skin sections.

22. The fuselage barrel assembly of claim 18, wherein each of the splice joints includes first and second splice plates respectively fastened to interior and exterior sides of the upper and lower composite skin sections.

23. The fuselage barrel assembly of claim 18, wherein each of the splice joints includes:

window frames respectively extending around the window openings and attached to each of the upper and lower skin sections, and

each of the window frames including longitudinally extending splice plate portions overlying and attached to each of the upper and lower composite skin sections.

24. A method of making a fuselage barrel assembly having windows located along longitudinal window belts, comprising:

fabricating an upper barrel half having an upper composite skin;

fabricating a lower barrel half having a lower composite skin; and

joining the upper and lower barrel halves, including splicing the upper and lower composite skins together along at the window belts.

25. The method of claim 24, further comprising:

forming ply pad-ups in the upper and lower composite skins along the window belts; and

forming window openings in the upper and lower composite skins within the ply pad-ups.

26. The method of claim 24, wherein fabricating the upper and lower barrel halves includes fabricating each of the upper and lower composite skins by laminating plies of fiber reinforced resin, and increasing the thickness of the laminated plies in the area of the window belts, and

wherein splicing the upper and lower composite skins together is performed within the area having the increased thickness of the laminated plies.

27. The method of claim 24, wherein splicing the upper and lower composite skins together includes:

overlapping edges of the upper and lower composite skins, and

adhesively bonding the overlapping edges together.

28. The method of claim 24, wherein splicing the upper and lower composite skins together includes:

bringing edges of the upper and lower composite skins together, and

co-curing to the upper and lower composite skins.

29. The method of claim 24, wherein splicing the upper and lower composite skins together includes bonding a composite splice strap to adjacent edges of the upper and lower composite skins.

30. The method of claim 24, wherein splicing the upper and lower composite skins together includes fastening the upper and lower composite skins between external and internal splice plates.

31. The method of claim 30, wherein:

fabricating each of the upper and lower barrel halves includes forming external longitudinal recesses in the upper and lower composite skins, and

fastening the upper and lower skins between the external and internal spice plates includes locating the external splice plate within the recesses.

32. The method of claim 24, further comprising:

fabricating a plurality of window frames, and

wherein splicing the upper and lower composite skins together includes mechanically connecting the upper and lower composite skins together by fastening the window frames to each of the upper and lower composite skins.

33. A method of making a fuselage barrel having windows located along longitudinal window belts, comprising:

fabricating a laminated composite fuselage skin, including fabricating upper and lower composite skin sections and forming ply pad-ups along edges of the upper and lower skin sections to increase the thickness of the fuselage skin along the window belts; and

assembling the upper and lower composite skin sections together, including forming longitudinal splice joints between the upper and lower skin sections at section within the ply pad-ups.

34. The method of claim 33, further comprising:

forming window cutouts in the fuselage skin within the ply pad-ups.

35. The method of claim 34, wherein the window cutouts are formed in the upper and lower skin sections before the upper and lower skin sections are assembled together.

36. The method of claim 34, wherein forming the splice joints includes:

installing window frames in the window cutouts, and

fastening the window frames to each of the upper and lower skin sections.

37. The method of claim 33, wherein forming the longitudinal splice joints includes joining the upper and lower skin sections by one of:

bonding, and

cc-curing.

38. The method of claim 33, wherein forming the longitudinal splice joints includes:

fastening splice plates to each of the upper and lower skin sections.

39. A method of making a fuselage barrel assembly having a window belt, comprising:

fabricating an upper barrel half having an upper composite skin;

fabricating a lower barrel half having a lower composite skin;

placing each of the upper and lower barrel halves in a splice assembly feature, including co-locating edges of the upper and lower skins; and

splicing together the edges of the upper and lower skins at the window belt.

40. The method of claim 39, wherein splicing the edges of the upper and lower skins is performed by adhesively bonding the edges together.

41. The method of claim 39, wherein splicing the edges of the upper and lower skins is performed by co-curing the upper and lower skins.

42. The method of claim 39, wherein splicing the edges of the upper and lower skins is performed by fastening splice plates between the upper and lower skins.

43. The method of claim 39, wherein splicing the edges includes overlapping and joining the edges of the upper and lower skins.

44. The method of claim 39, further comprising:

forming window cutouts in each of the upper and lower skins, and

wherein splicing the upper and lower skins together includes placing window frames in the window cutouts and fastening each of the window frames to each of the upper and lower skins.

45. The method of claim 39, wherein:

fabricating the upper and lower barrel halves includes forming a longitudinal recess in the edges of the upper and lower skins, and

splicing the edges together includes placing a splice plate in the recess and fastening the splice plate to each of the upper and lower skins.