Method of assembly of composite core sandwich edge joint

Patent metadata

Field	Value
Publication number	US-2018230693-A1
Application number	US-201715614041-A
Country	US
Kind code	A1
Filing date	Jun 5, 2017
Priority date	Feb 14, 2017
Publication date	Aug 16, 2018
Grant date	—

Abstract

A composite wall assembly edge joint, includes a first composite buildup pad secured to a first composite face sheet with the first composite buildup pad having a first tapered section with a first inclined surface which extends in a first direction and having a second section which extends from the first tapered section with a second surface which extends in a second direction, different from the first direction, toward a first end of the first composite face sheet. The assembly further includes a composite flute core member, having a tapered first portion secured to the first tapered section; a second portion secured to the first composite face sheet; and a third portion which extends in the second direction, away from the tapered first portion, toward the first end of the first composite face sheet secured to the second section.

First claim

What is claimed:

1 . A composite wall assembly edge joint, comprising:
a first composite buildup pad secured to a first composite face sheet with the first composite buildup pad having a first tapered section with a first inclined surface which extends in a first direction and having a second section which extends from the first tapered section with a second surface which extends in a second direction, different from the first direction, toward a first end of the first composite face sheet; and a composite flute core member, comprising:
a tapered first portion secured to the first tapered section of the first composite buildup pad;
a second portion which extends in a third direction away from the tapered first portion and is secured to the first composite face sheet; and
a third portion which extends in the second direction, away from the tapered first portion, toward the first end of the first composite face sheet secured to the second section of the first composite buildup pad.

2 . The composite wall assembly edge joint of claim 1 , further including:
a second composite buildup pad secured to a second composite face sheet wherein the first and second composite face sheets are spaced apart with the second composite buildup pad having a second tapered section with a second inclined surface which extends in a fourth direction and having a second section which extends from the second tapered section with a third surface which extends in a fifth direction, different from the fourth direction, toward a second end of the second composite face sheet, wherein:
the tapered first portion of the composite flute core member is positioned and secured between the first tapered sections of the first and second composite buildup pads respectively;
the second portion is positioned between the first and second composite face sheets and secured to the second composite face sheet; and
the third portion is positioned between the second section of the first composite buildup pad and the second section of the second composite buildup pad and secured to the second section of the second composite build up pad.

3 . The composite wall assembly edge joint of claim 2 , wherein:
the first composite buildup pad reduces in a thickness dimension as the first composite buildup pad extends in a sixth direction away from the first end of the first composite face sheet; and the second composite buildup pad reduces in a thickness dimension as the second composite buildup pad extends in a seventh direction away from the second end of the second composite face sheet such that the first and fourth directions extend in diverging directions from one another.

4 . The composite wall assembly edge joint of claim 2 , wherein:
the second and fifth directions extend in a same direction in relationship to one another; and the second section of the first composite buildup pad and the second section of the second composite buildup pad are spaced apart.

5 . The composite wall assembly edge joint of claim 2 , wherein:
the first composite buildup pad extends to the first end of the first composite face sheet; and the second composite buildup pad extends to the second end of the second composite face sheet.

6 . The composite wall assembly edge joint of claim 2 , wherein:
the third portion extends in a eighth direction toward the first end of the first composite face sheet and the second end of the second composite face sheet; and the third portion defines a first bore positioned through a first sidewall of the third portion aligned with a second bore defined and positioned through the first composite face sheet and the third portion defines a third bore positioned through a second sidewall of the third portion aligned with a fourth bore defined and positioned through the second composite face sheet.

7 . The composite wall assembly edge joint of claim 6 , wherein:
a bridge composite structure is positioned between and secured to the first and second sidewall of the third portion of the composite flute core member; and the bridge composite structure defines a fifth bore which extends through the bridge composite structure and aligns with the first bore, second bore, third bore and fourth bore.

8 . The composite wall assembly edge joint of claim 6 , wherein the third portion extends to the first end of the first composite face sheet and the second end of the second composite face sheet.

9 . The composite wall assembly edge joint of claim 2 , further including:
a second composite flute core member is positioned to extend between the first and second composite buildup pads and adjoins a third sidewall of the composite flute core member; and a third composite flute core member is positioned to extend between the first and second composite buildup pads and adjoins a fourth sidewall of the composite flute core member which opposes the third sidewall.

10 . The composite wall assembly edge joint of claim 9 , wherein the second composite flute core member and the third composite flute core member extend between the first and second composite build up pads to the first end of the first composite face sheet and the second end of the second composite face sheet.

11 . The composite wall assembly edge joint of claim 9 , wherein:
a first sidewall of the second composite flute core member which adjoins the first composite buildup pad and a second sidewall of the second composite flute core member which adjoins the second composite buildup pad reduce in dimension between the first sidewall and second side wall as the first and second sidewall of the second composite flute core member extend in a ninth direction toward the composite flute core member; and a first sidewall of the third composite flute core member which adjoins the first composite buildup pad and a second sidewall of the third composite flute core member which adjoins the second composite buildup pad reduce in dimension between the first sidewall and second sidewall as the first and second sidewall of the third composite flute core member extend in a tenth direction toward the composite flute core member.

12 . The composite wall assembly edge joint of claim 11 further including a fourth composite flute core member, wherein:
a first portion of the fourth composite flute core member is positioned to extend between the first and second composite buildup pads and adjoin the third composite flute core with a first sidewall of the first portion of the fourth composite flute core member adjoins the first composite buildup pad and extends in an eleventh direction of the first sidewall of the third composite flute core member and second sidewall of the first portion of the fourth composite flute core member adjoins the second composite buildup pad and extends in a twelfth direction of the second sidewall of the third composite flute core member;
a second portion of the fourth composite flute core member is positioned to extend between a third composite buildup member and a fourth composite buildup member; and
the first and third composite buildup members adjoin one another and the second and fourth composite buildup members adjoin one another.

13 . A method of for assembling a composite wall assembly edge joint, comprising:
laying up a first composite buildup pad onto a first composite face sheet with the first composite buildup pad having a first tapered section with a first inclined surface which extends in a first direction and having a second section which extends from the first tapered section with a second surface which extends in a second direction, different from the first direction, toward a first end of th

Assignees

• Boeing Co

Inventors

• Mccarville Douglas
• Guzman Juan Carlos
• Hand Michael Leslie
• Birkland Jordan O
• Dillon Alexandra K

Classifications

• E04C2/205 Primary

  of foamed plastics, or of plastics and foamed plastics, optionally reinforced · CPC title

• E04C2/32

  formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material · CPC title

• E04C2002/3455

  with trapezoidal corrugations · CPC title

• E04B1/6116 Primary

  by locking means on lateral surfaces · CPC title

• E04B1/6108

  the frontal surfaces of the slabs connected together · CPC title