Structures using composite modules and structures made thereby

Patent metadata

Field	Value
Publication number	US-9764499-B2
Application number	US-201414231745-A
Country	US
Kind code	B2
Filing date	Apr 1, 2014
Priority date	Dec 7, 2007
Publication date	Sep 19, 2017
Grant date	Sep 19, 2017

Abstract

A large scale composite structure is fabricated by forming a plurality of composite laminate modules and joining the modules together along their edges using scarf joints.

First claim

What is claimed is:

1. An aircraft structure fabricated by a method comprising:
forming a plurality of modules each having an edge, each of the plurality of modules comprising a plurality of adjacently stacked uncured composite pre-preg fibers, each of said plurality of modules being substantially planar;
joining the plurality of modules together by joining respective edges of two adjacently positioned modules to form a scarf joint between said adjacently positioned modules, said respective edges are substantially co-planar, wherein the scarf joint forms crenulated patterns arranged in at least two groups staggered relative to each other such that a phase of the at least two groups is offset by a distance so that adjacent ones of the crenulated patterns are not aligned with each other, wherein an assembly is formed; and
co-curing the assembly.

2. A composite structure for aircraft, comprising:
a plurality of composite laminate modules each having edges; and
scarf joints joining the modules along their edges, wherein the scarf joints form crenulated patterns arranged in at least two groups staggered relative to each other such that a phase of the at least two groups is offset by a distance so that adjacent ones of the crenulated patterns are not aligned with each other.

3. The composite structure of claim 2 , wherein:
each of the modules includes multiple plies, and
like plies in adjoining ones of the modules abut each other at the scarf joint.

4. The composite structure of claim 2 , wherein:
each of the modules includes multiple plies, and
like plies in adjoining ones of modules overlap at the scarf joint.

5. The composite structure of claim 2 , wherein the scarf joint is a finger joint.

6. The composite structure of claim 2 , wherein:
at least certain of the modules having edges joined together by the scarf joints each include at least one ply including reinforcing fibers having a common orientation.

7. The composite structure of claim 2 , further comprising:
at least one ply of composite material overlying and joined to at least one of the scarf joints.

8. A composite structure for aircraft, comprising:
a plurality of co-cured composite laminate modules each including multiple plies of fiber reinforced resin, each of the modules including first and second edges extending traverse to each other,
ply edges of adjacent ones of the modules overlapping each other to form a scarf joint joining the adjacent modules together, wherein the scarf joint forms crenulated patterns arranged in at least two groups staggered relative to each other such that a phase of the at least two groups is offset by a distance so that adjacent ones of the crenulated patterns are not aligned with each other, and
at least certain of the adjacent modules including plies having fiber reinforcement oriented traverse to the edges and wherein the first and second edges form a crenulated pattern.

Assignees

• Boeing Co

Inventors

• Jones Darrell D
• Berg Arvid J
• Brennan Joseph D
• Sherwood Travis J

Classifications

• Y10T29/49622

  Vehicular structural member making · CPC title

• B29C70/30

  Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core · CPC title

• B29K2105/0872

  Prepregs · CPC title

• B29C70/38

  Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns {(application heads for tyres B29D30/28)} · CPC title

• Y10T156/1052

  with cutting, punching, tearing or severing · CPC title