Method of assembly of composite core sandwich edge joint

Patent metadata

Field	Value
Publication number	US-10279550-B2
Application number	US-201715468793-A
Country	US
Kind code	B2
Filing date	Mar 24, 2017
Priority date	Feb 14, 2017
Publication date	May 7, 2019
Grant date	May 7, 2019

Abstract

A method for assembling a composite wall assembly edge joint including laying up a first composite face sheet, laying up a first composite buildup pad having a first tapered section onto the first composite face sheet and positioning a composite flute core member, including a tapered first portion with a first inclined surface and a second inclined surface. First inclined surface is positioned onto the first tapered section of the first composite buildup pad and a second portion of the composite flute core member extends from the tapered first portion along first composite face sheet. The method also includes laying up a second composite buildup pad having a second tapered section with the second composite buildup pad spaced apart from the first composite buildup pad and having at least a portion of the second tapered section overlying the second inclined surface of the tapered first portion.

First claim

What is claimed:

1. A method for assembling a composite wall assembly edge joint, comprising steps of:
laying up a first composite face sheet;
laying up a first composite buildup pad having a first tapered section onto the first composite face sheet;
positioning a composite flute core member, comprising a tapered first portion comprising a first inclined surface and a second inclined surface wherein:
the first inclined surface of the composite flute core member is positioned onto the first tapered section of the first composite buildup pad; and
a second portion of the composite flute core member extends from the tapered first portion along first composite face sheet; and

laying up a second composite buildup pad having a second tapered section wherein the second composite buildup pad is positioned spaced apart from the first composite buildup pad having at least a portion of the second tapered section of the second composite buildup pad overlying the second inclined surface of the tapered first portion of the composite flute core member.

2. The method for assembling of claim 1 , wherein the step of laying up the first buildup pad further including the step of laying up of the first buildup pad to extend in a direction away from a first end of the first composite face sheet with the first tapered section having a thickness reducing in dimension as the first composite buildup pad extends in a direction away from the first end.

3. The method for assembling for claim 2 , wherein the step of positioning of the composite flute core member further including positioning the first inclined surface of the composite flute core member overlying the first tapered section of the first composite buildup pad such that the first inclined surface of the composite flute core member increases in distance away from the first composite face sheet as the composite flute core member extends in a direction toward the first end of the first composite sheet face.

4. The method for assembling of claim 3 , wherein the step of laying up the second composite buildup pad having the second tapered section including configuring the second tapered section with the second tapered section reducing in thickness as the second composite buildup pad extends in a direction away from the first end of the first composite face sheet with the second inclined surface of the tapered first portion of the composite flute core member positioned closer to the first composite face sheet as the second inclined surface of the composite flute core member extends in a direction toward the first end of the first composite face sheet.

5. The method for assembling of claim 1 , further including a step of supporting an interior surface of the tapered first portion and the second portion of the composite flute core member.

6. The method for assembling of claim 5 , wherein the step of supporting including a step of inserting a pressurized gas into an interior of the composite flute core member.

7. The method for assembling of claim 5 , wherein the step of supporting including a step of inserting a collapsible support structure into the interior of the composite flute core member supporting the interior surface of the first portion and the second portion of the flute core member.

8. The method for assembling of claim 1 , further including a step of positioning a support structure within space between the first composite buildup pad and the second composite buildup pad.

9. The method for assembling of claim 1 , further including a step of laying up a second composite face sheet onto the second composite buildup pad and onto the second portion of the composite flute core member which extends from the tapered first portion of the composite flute core member.

10. The method for assembling of claim 9 , further including a step of heating the first composite face sheet, first composite buildup pad, the composite flute core member; and the second composite buildup pad and the second composite face sheet.

11. The method for assembling of claim 10 , further including a step of laying up a composite bridge structure and post bonding the composite bridge structure to the first and second composite buildup pads.

12. The method for assembling of claim 11 , further including a step of drilling a first hole in a first direction through the first composite face sheet, the first composite buildup pad, the composite bridge structure, the second composite buildup pad and the second composite face sheet.

13. The method for assembling of claim 12 , further including a step of drilling a first portion of a second hole in the composite bridge structure in a second direction transverse to the first direction placing the first portion in communication with the first hole and drilling a second portion of the second hole positioned spaced apart from the first portion of the second hole across the first hole and aligned with the first portion of the second hole.

14. The method for assembling of claim 13 , further including a step of inserting a barrel nut into the first hole and inserting a bolt into the second hole and securing the bolt to the barrel nut.

15. A method for assembling a composite wall assembly edge joint, comprising steps of:
laying up a composite first face sheet;
laying up a composite first buildup pad having a first tapered section onto the composite first face sheet;
positioning a cured composite flute core member, comprising a tapered first portion comprising a first inclined surface and a second inclined surface, wherein
the first inclined surface of the cured composite flute core member is positioned onto the first tapered section of the composite buildup pad with an adhesive film positioned between the first inclined surface and first tapered section; and
a second portion of the composite flute core member extends from the tapered first portion along first composite face sheet wherein an adhesive film is positioned between the second portion of the composite flute core member and the first composite face sheet; and

laying up a second composite buildup pad having a second tapered section wherein the second composite buildup pad is positioned spaced apart from the first composite buildup pad having at least a portion of the second tapered section overlying the second inclined surface of the tapered first portion of the composite flute core member with an adhesive layer positioned between the second tapered section and the second inclined surface of the tapered first portion of the composite flute core member.

16. The method for assembling of claim 15 , further including a step of positioning a support structure between the spaced apart first composite buildup pad and the second composite buildup pad.

17. The method for assembling of claim 15 , further including a step of laying up a second composite face sheet onto the second composite build up pad and in overlying relationship with the second portion of the cured composite flute core member with an adhesive film positioned between the second composite face sheet and the second portion of the composite flute core member.

18. The method for assembling of claim 17 , further including a step of heating the first composite face sheet, the first composite buildup pad, the composite flute core member, the second composite buildup pad and the second composite face sheet.

19. The method for assembling of claim 18 , further including a step of laying up a composite bridge structure and post bonding the composite bridge structure to the first and second composite bui

Assignees

• Boeing Co

Inventors

• Guzman Juan Carlos
• Hand Michael Leslie
• Mccarville Douglas

Classifications

• F16B11/006

  by gluing (gluing of plastics material B29C65/48) · CPC title

• Y10T428/195

  Beveled, stepped, or skived in thickness · CPC title

• B29C70/682 Primary

  Preformed parts characterised by their structure, e.g. form · CPC title

• F16B5/121

  fastened over the edge(s) of the sheet(s) or plate(s) · CPC title

• B29C70/545

  Perforating, cutting or machining during or after moulding · CPC title