Method and apparatus for joining composite structures

Patent metadata

Field	Value
Publication number	US-8973241-B1
Application number	US-201213605604-A
Country	US
Kind code	B1
Filing date	Sep 6, 2012
Priority date	Sep 6, 2012
Publication date	Mar 10, 2015
Grant date	Mar 10, 2015

Abstract

A method and apparatus for forming a joint between a first composite structure and a second composite structure. A number of tab sections may be formed at an end of the first composite structure. The first composite structure may comprise a first skin, a second skin, and a core located between the first skin and the second skin. A tab section in the number of tab sections may comprise a first skin section of the first skin, a second skin section of the second skin, and a core section of the core. A portion of the core section may be removed from each tab section to form a number of tabs at the end of the first composite structure. The first composite structure may be attached to the second composite structure using the number of tabs to form the joint between the first composite structure and the second composite structure.

First claim

What is claimed is:

1. A method for forming a joint between a first composite structure and a second composite structure, the method comprising:
forming a number of tab sections at an end of the first composite structure in which the first composite structure comprises a first skin, a second skin, and a core located between the first skin and the second skin and in which a tab section in the number of tab sections comprises a first skin section of the first skin, a second skin section of the second skin, and a core section of the core;
removing a portion of the core section from each tab section in the number of tab sections to form a number of tabs at the end of the first composite structure; and
attaching the first composite structure to the second composite structure using the number of tabs at the end of the first composite structure to form the joint between the first composite structure and the second composite structure.

2. The method of claim 1 further comprising:
forming a number of slots in the second composite structure in which each slot in the number of slots is configured to receive a tab in the number of tabs.

3. The method of claim 2 , wherein the step of forming the number of slots in the second composite structure comprises:
forming the number of slots at a first surface of the second composite structure in which the each slot in the number of slots extends towards a second surface of the second composite structure without reaching the second surface.

4. The method of claim 3 , wherein the step of attaching the first composite structure to the second composite structure using the number of tabs at the end of the first composite structure to form the joint between the first composite structure and the second composite structure comprises:
inserting the number of tabs at the end of the first composite structure into the number of slots in the second composite structure to form the joint.

5. The method of claim 4 , wherein the step of attaching the first composite structure to the second composite structure using the number of tabs at the end of the first composite structure to form the joint between the first composite structure and the second composite structure further comprises:
applying adhesive within the number of slots in the second composite structure prior to inserting the number of tabs at the end of the first composite structure into the number of slots in the second composite structure.

6. The method of claim 1 , wherein the step of removing the portion of the core section from the each tab section in the number of tab sections to form the number of tabs at the end of the first composite structure comprises:
removing the portion of the core section from the each tab section and at least one of a portion of the first skin section and a portion of the second skin section from the each tab section to form the number of tabs at the end of the first composite structure.

7. The method of claim 1 , wherein the step of removing the portion of the core section from the each tab section in the number of tab sections to form the number of tabs at the end of the first composite structure comprises:
removing the core section entirely and the first skin section entirely from the each tab section in the number of tab sections to form the number of tabs.

8. The method of claim 7 , wherein the step of attaching the first composite structure to the second composite structure using the number of tabs at the end of the first composite structure to form the joint between the first composite structure and the second composite structure comprises:
applying adhesive to an end of the second composite structure; and
attaching the number of tabs to the end of the second composite structure such that an edge of the core of the first composite structure contacts a surface of the second composite structure.

9. The method of claim 1 , wherein the step of removing the portion of the core section from the each tab section in the number of tab sections to form the number of tabs at the end of the first composite structure comprises:
removing the core section entirely and a portion of the first skin section from the each tab section in the number of tab sections to form the number of tabs.

10. The method of claim 9 , wherein the step of attaching the first composite structure to the second composite structure using the number of tabs at the end of the first composite structure to form the joint between the first composite structure and the second composite structure comprises:
applying adhesive within a number of slots in the second composite structure and to an end of the second composite structure; and
inserting a first portion of the number of tabs into the number of slots in the second composite structure such that a second portion of the number of tabs contacts and adheres to the end of the second composite structure.

11. The method of claim 1 , wherein performing the steps of forming the number of tab sections at the end of the first composite structure and removing the portion of the core section from the each tab section in the number of tab sections to form the number of tabs at the end of the first composite structure forms an edge for the core of the first composite structure in which the edge of the core is configured to substantially conform to a surface of the second composite structure when the first composite structure is attached to the second composite structure.

12. A method for forming a joint between a first composite structure and a second composite structure, the method comprising:
forming a number of tab sections at an end of the first composite structure in which the first composite structure comprises a first skin, a second skin, and a core located between the first skin and the second skin and in which a tab section in the number of tab sections comprises a first skin section of the first skin, a second skin section of the second skin, and a core section of the core;
removing a portion of the core section from each tab section in the number of tab sections to form a number of tabs at the end of the first composite structure;
forming a number of slots at a first surface of the second composite structure in which each slot in the number of slots extends towards a second surface of the second composite structure without reaching the second surface;
applying adhesive within the number of slots in the second composite structure; and
inserting the number of tabs at the end of the first composite structure into the number of slots in the second composite structure to form the joint between the first composite structure and the second composite structure in which an edge of the core of the first composite structure substantially conforms to the first surface of the second composite structure when the first composite structure is attached to the second composite structure.

Assignees

• Gooch Paul L
• Boeing Co

Inventors

• Gooch Paul L

Classifications

• F16B12/125

  using mortise and tenon joints · CPC title

• B64D11/00

  Passenger or crew accommodation; Flight-deck installations not otherwise provided for · CPC title

• B64D11/003 Primary

  Stowage devices for passengers' personal luggage · CPC title

• F16B12/04 Primary

  Non-loosenable joints for non-metal furniture parts, e.g. glued · CPC title

• Y10T428/19

  Sheets or webs edge spliced or joined · CPC title