Stiffened stringer panel with integral indexing laminate stacks

Patent metadata

Field	Value
Publication number	US-10442153-B2
Application number	US-201715852912-A
Country	US
Kind code	B2
Filing date	Dec 22, 2017
Priority date	Dec 22, 2017
Publication date	Oct 15, 2019
Grant date	Oct 15, 2019

Abstract

Provided are stiffened stringer panels with integrated indexing stacks. An example composite panel comprises a skin member having an inner surface. An index for positioning a support tool comprises a first set and second set of layered laminate stacks coupled to the inner surface such that a channel is formed between the first and second set of layered laminate stacks. The first and second set of layered laminate stacks is configured to cradle a support tool in the channel to automatically align the support tool relative to the panel. A stringer may include a cap portion that extends from the first set to the second set of layered laminate stacks to form flange portions on the inner surface of the skin member. The index and the skin member may be co-cured or co-bonded.

First claim

What is claimed is:

1. A composite panel comprising:
a skin member having an inner surface,
an index coupled to the inner surface of the skin member for positioning a support tool on the inner surface, the index comprising:
a first index stack of a first plurality of index plies,
a second index stack of a second plurality of index plies, and
a channel formed between an interior side of each of the first index stack and the second index stack,
wherein the first index stack and the second index stack are configured to cradle a support tool in the channel; and
wherein each of the first plurality of index plies and the second plurality of index plies comprises an elongated base ply as a bottom layer containing the inner surface of the skin member, wherein an upper surface of each elongated base ply is substantially exposed from the respective plurality of index plies; and

a stringer comprising:
a cap portion extending from an exterior side of the first index stack to an exterior side of the second index stack,
a first flange portion extending from a first side of the cap portion, the first flange portion located upon the upper surface of the elongated base ply of the first plurality of index plies, and
a second flange portion extending from a second side of the cap portion, the second flange portion located upon the upper surface of the elongated base ply of the second plurality of index plies.

2. The composite panel of claim 1 , wherein the stringer comprises a cover laminate including a plurality of stringer plies.

3. The composite panel of claim 1 , wherein the first index stack and the second index stack are configured to cradle the support tool such that the support tool lies flush against a portion the interior side of each of the first index stack and the second index stack.

4. The composite panel of claim 1 , wherein the index and the skin member are co-cured.

5. The composite panel of claim 1 , wherein the index and the skin member are co-bonded.

6. The composite panel of claim 1 , wherein the support tool is a forming mandrel.

7. The composite panel of claim 1 , wherein each index stack comprises composite fibers pre-impregnated with a resin system.

8. The composite panel of claim 1 , wherein the support tool is automatically aligned within the index.

9. The composite panel of claim 1 ,
wherein a first filler is positioned on top of a first top index ply of the first plurality of index plies, and a second filler is positioned on top of a second top index ply of the second plurality of index plies.

10. A method of manufacturing a stiffened composite panel, the method comprising:
providing a skin member having an inner surface;
constructing a first index stack on the inner surface of the skin member, wherein the first index stack comprises a first plurality of index plies, wherein the first index stack is constructed by consecutively depositing groupings of one or more of the first plurality of index plies upon the inner surface of the skin member;
constructing a second index stack on the inner surface of the skin member, wherein the second index stack comprises a second plurality of index plies, wherein the second index stack is constructed by consecutively depositing groupings of one or more of the second plurality of index plies upon the inner surface of the skin member; forming an index with the first stack and the second index stack, the index comprising an index channel between an interior side of each of the first index stack and the second index stack, wherein the index is configured to cradle a support tool in the index channel;
aligning the support tool within the index channel;
depositing one or more stringer plies onto each the support tool, the first index stack, and the second index stack to form a stringer; and
joining the skin member, the first index stack, the second index stack, and the stringer plies.

11. The method of claim 10 , wherein the stringer comprises a cap portion that spans from the first index stack to the second index stack to form a first flange portion and a second flange portion on the inner surface of the skin member, each flange portion extending from the cap portion.

12. The method of claim 11 , wherein the index and the skin member are co-cured or co-bonded.

13. The method of claim 10 , wherein the first index stack and the second index stack are configured to cradle the support tool such that the support tool lies flush against a portion of the interior side of each of the first index stack and the second index stack.

14. The method of claim 10 , wherein the support tool is a forming mandrel.

15. The method of claim 10 , wherein each of the first index stack and the second index stack comprises composite fibers pre-impregnated with a resin system.

16. The method of claim 10 , wherein the support tool is automatically aligned within the index channel.

17. The method of claim 10 , further comprising:
positioning a first filler on top of a first top index ply of the first plurality of index plies of the first index stack, and
positioning a second filler on top of a second top index ply of the second plurality of index plies of the second index stack.

18. The method of claim 10 , wherein the stringer comprises:
a cap portion extending from the first index stack to the second index stack,
a first flange portion extending from a first side of the cap portion, the first flange portion located upon a first elongated base ply of the first index stack,
a second flange portion extending from a second side of the cap portion, the second flange portion located upon a second elongated base ply of the second index stack,
wherein the first elongated base ply and the second elongated base ply form a bottom layer of the first index stack and the second index stack, respectively.

19. The method of claim 10 , wherein each of the first plurality of index plies and the second plurality of index plies are automatically aligned and deposited onto the inner surface of the skin member by a robotic assembly system.

20. An aircraft comprising one or more composite panels, the one or more composite panels comprising:
a skin member having an inner surface,
an index coupled to the inner surface of the skin member for positioning a support tool on the inner surface, the index comprising: a first index stack of a first plurality of index plies, a second index stack of a second plurality of index plies, and a channel formed between an interior side of each of the first index stack and the second index stack, wherein the first index stack and the second index stack are configured to cradle a support tool in the channel; and
wherein each of the first plurality of index plies and the second plurality of index plies comprises an elongated base ply as a bottom layer contacting the inner surface of the skin member, wherein an upper surface of each elongated base ply is substantially exposed from the respective plurality of index plies; and
a stringer comprising: a cap portion extending from an exterior side of the first index stack to an exterior side of the second index stack, a first flange portion extending from a first side of the cap portion, the first flange portion located upon the upper surface of the elongated base ply of the first plurality of index plies, and a second flange portion extending from a second side the cap portion, the second flange portion located upon the upper surface of the elongated base ply of the second plurality of index plies.

Assignees

• Boeing Co

Inventors

• Shinozaki John M
• Stickler Patrick B
• Chungbin Jerry D

Classifications

• B64C2001/0072

  from composite materials · CPC title

• B64C1/12

  Construction or attachment of skin panels · CPC title

• B29D99/0014 Primary

  provided with ridges or ribs, e.g. joined ribs · CPC title

• B32B2305/076

  Prepregs · CPC title

• B64C3/182

  Stringers, longerons · CPC title