Method for manufacturing a solid laminated stringer on a composite panel

Abstract

A method for manufacturing a solid laminated stringer on a composite panel, the method comprising unwinding one or more composite layers onto the composite panel; compressing the one or more composite layers unwound onto the composite panel; cutting the one or more composite layers unwound onto the composite panel; and curing the one or more composite layers unwound onto the composite panel, wherein the one or more composite layers are continuously unwound along a length corresponding to the length of the solid laminated stringer.

Description

TECHNICAL FIELD

[0001] The present disclosure generally relates to solid laminated stringers, and more particularly to methods for manufacturing solid laminated stringers on composite panels. BACKGROUND ART

[0002] Solid laminated stringers are used in the aerospace industry as structural components of aircraft and / or for reinforcing composite panels, such as fuselage, skin, and / or wing sections. Solid laminated stringers can be formed by stacking multiple layers of composite materials, such as resin-impregnated carbon fiber reinforced plies.

[0003] However, current methods for manufacturing solid laminated stringers require manual or semi-manual placement of composite material layers or plies, may be limited to straight and / or constant-width composite material layers or plies, and may require splicing of composite material layers or plies considering the curvature of the composite panel or the total length of the solid laminated stringer. Additionally, manual or semi-manual placement and splicing may result in defects and wrinkles due to splicing or misalignment of composite material layers or plies on curved surfaces during curing. The additional labor required for manual or semi-manual placement and splicing makes it difficult to meet the high-volume and high-rate production of current aircraft structures.

[0004] Accordingly, there is a need for an improved method for manufacturing solid laminated stringers that is less labor-intensive and can accommodate the width, length, and curvature of composite panels without splicing. SUMMARY OF THE INVENTION

[0005] This summary of the invention is only intended to provide a brief overview of some aspects of one or more implementations of the present disclosure. This summary is not an extensive review, nor is it intended to identify key or important elements of the teachings, nor to delineate the scope of the present disclosure. Instead, its purpose is only to present one or more concepts in a simplified form as a prelude to the following detailed description.

[0006] The foregoing and / or other aspects and utilities illustrated in the present disclosure can be achieved by providing a method for manufacturing a solid laminated stringer on a composite panel, the method including unwinding one or more composite layers onto the composite panel; compressing the one or more composite layers unwound onto the composite panel; cutting the one or more composite layers unwound onto the composite panel; and curing the one or more composite layers unwound onto the composite panel, wherein the one or more composite layers are continuously unwound along a length corresponding to the length of the solid laminated stringer.

[0007] Unwinding one or more composite layers onto the composite panel may include synchronizing the unwinding of the one or more composite layers using an overhead laser projection based on at least one of a moving speed, a rotation rate, a compressing pressure, and a heating temperature.

[0008] Unwinding one or more composite layers onto the composite panel may further include aligning at least one of an edge and a centerline of one or more composite layers on the composite panel to a curved line.

[0009] Unwinding one or more composite layers onto the composite panel may include performing the unwinding along a pre-set substantially straight and slightly curved line using a computer-controlled reel according to at least one of a pre-determined moving speed, rotation rate, compaction pressure, and heating temperature.

[0010] Curing one or more composite layers unwound onto the composite panel may include placing a vacuum bag over the one or more composite layers and applying a compaction pressure to the one or more composite layers.

[0011] The vacuum bag may cover at least a portion of the composite panel, and curing the one or more composite layers unwound onto the composite panel may further include curing the composite panel simultaneously.

[0012] The solid laminated girder may include two or more composite layers, and each of the two or more composite layers may include one or more composite plies.

[0013] The two or more composite layers may include wound prepregs.

[0014] Each of the two or more composite layers may be wound according to a laying design of the solid laminated girder, and the lengths of the two or more composite layers may at least correspond to the length of the solid laminated girder.

[0015] The solid laminated girder does not include spliced composite layers.

[0016] The width of the solid laminated girder may be from about 25 mm to about 150 mm.

[0017] The solid laminated girder may include one or more transverse edges, and the one or more transverse edges may include an inclination angle of from about 12° to about 75°.

[0018] The solid laminated girder may include one or more concave or convex bends along at least one of the x-axis, y-axis, and z-axis.

[0019] The bend along the x-axis may have a radius of from about 100 inches to about 10 20 inches.

[0020] The bend along the y-axis may have a radius of from about 20 inches to about 10 20 inches.

[0021] The one or more composite layers may include at least one of a base wrap layer and a top wrap layer.

[0022] The foregoing and / or other aspects and utilities illustrated in the present disclosure may also be achieved by providing a method for winding a composite layer, the method including placing one or more composite sheets on a forming table; trimming the one or more composite sheets placed on the forming table; compacting the one or more composite sheets placed on the forming table; and winding the compacted one or more composite sheets onto a reel, wherein the one or more composite sheets are placed continuously along the length of the forming table.

[0023] Placing the one or more composite sheets on the forming table may include placing the one or more composite sheets via automated fiber placement (AFP) or automated tape laying (ATL).

[0024] Trimming the one or more composite sheets placed on the forming table may include at least one of the following steps: trimming the one or more composite sheets to define a composite layer having two or more widths; trimming the one or more composite sheets to define a composite layer having a transverse edge with an inclination angle between about 12° and about 75°; trimming the one or more composite sheets to define a composite layer having substantially symmetric transverse edges; and trimming the one or more composite sheets to define the length of the composite layer.

[0025] The compacted one or more composite sheets form a prepreg composite layer, and wherein winding the compacted one or more composite sheets onto a reel includes winding the prepreg composite layer according to a laying design for a solid laminated girder.

[0026] From the detailed description provided below, further application areas will become apparent. It should be understood that the detailed description and specific examples, while indicating preferred examples of the present disclosure, are intended for illustrative purposes only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The drawings incorporated in and constituting a part of this specification illustrate implementations of the present teachings and, together with the description, are used to explain the principles of the present disclosure. In the drawings:

[0028] Figure 1 A composite panel having a solid laminated girder according to one implementation of the present disclosure is shown.

[0029] Figure 2 A curved solid laminated girder on a composite panel according to one implementation is shown.

[0030] Figure 3Shows a close-up of a solid laminated stringer on a composite panel according to one implementation.

[0031] Figure 4 Shows a transverse cross-sectional view of a solid laminated stringer on a composite panel according to one implementation.

[0032] Figure 5 Shows a longitudinal stacking configuration of composite layers forming a solid laminated stringer according to one implementation.

[0033] Figure 6 Shows a transition end of a solid laminated stringer according to one implementation.

[0034] Figure 7 Shows a longitudinal cross-sectional view of a transition end of a solid laminated stringer according to one implementation.

[0035] Figure 8 Shows a system for forming a solid laminated stringer on a composite panel according to one implementation.

[0036] Figure 9 Shows a system for forming multiple solid laminated stringers on a composite panel according to one implementation.

[0037] Figure 10 Shows a method for forming a solid laminated stringer on a composite panel according to one implementation.

[0038] Figure 11 Shows a system for winding composite layers according to one implementation.

[0039] Figure 12 Shows a method for winding composite layers according to one implementation.

[0040] Figure 13 Shows a flowchart of a method for aircraft production and maintenance according to one implementation.

[0041] Figure 14 Shows a block diagram of an aircraft according to one implementation.

[0042] It should be noted that some details of the drawings have been simplified and drawn to facilitate understanding of this teaching rather than to maintain strict structural accuracy, details, and proportions. Detailed Description

[0043] Reference will now be made in detail to the exemplary implementations of this teaching, examples of which are illustrated in the accompanying drawings. Generally, the same reference numerals are used throughout the drawings to denote the same or similar components.

[0044] Throughout the specification and claims, unless the context otherwise clearly dictates, the following terms are employed with the meanings explicitly associated herein. As used herein, phrases such as "in one implementation," "in certain implementations," and "in some implementations" do not necessarily refer to the same implementation, although they may. Additionally, phrases such as "in another implementation" and "in some other implementations" as used herein do not necessarily refer to different implementations, although they may. As described below, various implementations can be readily combined without departing from the scope or spirit of the present disclosure.

[0045] As used herein, the word "or" is an inclusive operator and is equivalent to the phrase "and / or" unless the context clearly dictates otherwise. The phrase "based on" is not exclusive and allows for additional factors not described unless the context clearly dictates otherwise. In the specification, a recitation of "at least one of A, B, and C" includes implementations that contain A, B, or C, multiple instances of A, B, or C, or combinations such as A / B, A / C, B / C, A / B / B / B / B / / C, A / B / C, etc. Additionally, throughout the specification, the meanings of "a," "an," and "the" include plural references. The meaning of "in" includes "in" and "on." "

[0046] It will also be understood that although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the present disclosure, a first object, component, or step may be referred to as a second object, component, or step, and similarly, a second object, component, or step may be referred to as a first object, component, or step. The first object, component, or step and the second object, component, or step are each an object, component, or step, but they are not considered the same object, component, or step. It will also be understood that when the words "comprises," "comprising," "has," and / or "containing" are used in this specification, they specify the presence of the stated features, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and / or groups thereof. Additionally, as used herein, the word "if" can be interpreted to mean "when," "after," "in response to determining," or "in response to detecting," depending on the context.

[0047] Unless otherwise specified, all physical properties defined below are measured at 20°C to 25°C.

[0048] When any numerical range is recited herein, such range is understood to include each and every value and / or fraction between the minimum and maximum values of said range, as well as the endpoints. For example, a range of 0.5% to 6% will explicitly include all intermediate values such as 0.6%, 0.7% and 0.9%, all the way up to and including 5.95%, 5.97% and 5.99%, and many other values. The same applies to every other numerical property and / or element range described herein, unless the context otherwise clearly dictates.

[0049] Additionally, all numerical values are “about” or “approximate” the values shown, and account for experimental error and variations to be expected by a person of ordinary skill in the art. It should be understood that all numerical values and ranges disclosed herein are approximate values and ranges. The terms “about” or “substantially” and “substantially the same” or “approximate” with respect to a quantity or measurement value mean that the recited characteristic, parameter, or value need not be exactly achieved. Rather, deviations or variations, including for example tolerances, measurement error, measurement precision limitations, and other factors known to persons of skill in the art, may occur in amounts that do not preclude the effect the characteristic is intended to provide.

[0050] Unless otherwise indicated, all percentages and amounts expressed herein and elsewhere in the specification are to be understood as being by weight percentage. The given percentages and amounts are based on the active weight of the materials. For example, for an active ingredient provided in solution form, the amount given is based on the amount of the active ingredient without solvent, or may be determined by weight loss upon evaporation of the solvent.

[0051] With respect to processes, methods, techniques, and workflows in accordance with some implementations, some of the operations in the programs, methods, techniques, and workflows disclosed herein may be combined and / or the order of some operations may be changed.

[0052] The inventors have created a new method for manufacturing solid laminated stringers on a composite panel. In some implementations, the method uses an automated digitally modeled controlled process to simultaneously wind, unwind, compact, and cure multiple solid laminated stringers directly as a single-piece composite structure on a skin substrate. The method can streamline the manufacturing process by eliminating the manual or semi-manual placement and splicing of composite layers when they are placed on a curved surface. The method can reduce the labor required, minimize damage, errors, and consequent defects and wrinkling during high-quality manufacturing and safe integration of composite components. The method can require less labor, materials, and manufacturing floor space, and can reduce the associated manufacturing costs to enable high-volume production at high rates.

[0053] Figure 1 A composite panel with solid laminated stringers in accordance with one implementation of the present disclosure is shown. Figure 2Shows a bent solid laminated stringer on a composite panel according to one implementation.

[0054] Figure 3 Shows a close-up of a solid laminated stringer on a composite panel according to one implementation. Figure 4 Shows a transverse cross-sectional view of a solid laminated stringer on a composite panel according to one implementation. As Figures 1 to 4 shown, one or more solid laminated stringers 100 may be formed on the composite panel 50, and each solid laminated stringer 100 may include two or more composite layers 110.

[0055] Each solid laminated stringer 100 may include two or more, three or more, four or more, five or more, six or more, seven or more, eight or more, nine or more, or 10 or more composite layers 110. For example, the solid laminated stringer 100 may include from 2 to about 20 composite layers 110. In other implementations, the solid laminated stringer 100 may include 20 or fewer, 15 or fewer, 10 or fewer, or six or fewer composite layers 110. For example, the solid laminated stringer 100 may include 4 composite layers 110, 5 composite layers 110, or 6 composite layers 110.

[0056] For example, as Figures 3 to 4 shown, the solid laminated stringer 100 may include a first composite layer 111, a second composite layer 112, a third composite layer 113, and a fourth composite layer 114.

[0057] The composite layer 110 may include a strong, lightweight material produced by combining two or more functional components that can be cured into a single structure. For example, the composite layer 110 may include a filler incorporated in a resin matrix. The resin for the composite layer 110 may include a thermoplastic or thermosetting resin, such as an epoxy resin. The filler may be of reinforcing or non-reinforcing nature and may be of various shapes, such as powder, granules, flakes, foam, nanotubes or microtubes, continuous and discontinuous fiber-reinforced strips or fabrics, etc.

[0058] In one implementation, the composite layer 110 includes plies or composite plies of carbon fiber-reinforced composite material. For example, as Figure 3 shown, the composite layer 110 may include one or more composite plies 400. The composite ply 400 may be made of unidirectional composite strip material impregnated with epoxy resin.

[0059] In other implementations, the composite ply 400 may be made of woven fabric material finished with resin, such as glass fiber, carbon, or aramid fabric infused with epoxy resin.

[0060] The composite layer 110 may include prepreg. As used herein, the term "prepreg" refers to a pre-impregnated stack of composite plies, such as epoxy-impregnated unidirectional composite strips. The prepreg can be flexible until it is cured, typically by heating and applying pressure or by curing in an autoclave.

[0061] Each composite layer 110 may include one or more composite plies 400. The composite layer 110 may include 1 or more, 2 or more, 3 or more, 4 or more, 5 or more, 6 or more, 7 or more, 8 or more, 9 or more, or 10 or more composite plies 400. In other implementations, the composite layer 110 may include 20 or fewer, 15 or fewer, 10 or fewer, or five or fewer composite plies 400. For example, the composite layer 110 may include 1 composite ply, 2 composite plies, or 3 composite plies.

[0062] The composite plies 400 forming each composite layer 110 may have a conventional orientation layup. For example, the composite plies 400 may be positioned at an angle to the x-axis of the solid laminated girder 100, the angles including 0°, 45°, -45°, and 90°. In other implementations, the composite plies 400 forming each composite layer 110 may have a non-conventional orientation layup, and / or a mixture of conventional and non-conventional orientation layups. The number of composite plies 400 positioned at these orientation angles may be evenly distributed or may not be evenly distributed. Thus, each composite layer 110 may include one or more composite plies 400, and the one or more composite plies 400 may have different orientations.

[0063] The composite panel 50 may also include a strong, lightweight material produced by combining two or more functional components that can be cured into a single structure. For example, the composite panel 50 may include multiple composite layers that are laminated and cured into a single structure. The composite panel 50 may be configured to be compatible with and / or bond to the solid laminated girder 100 upon curing.

[0064] In some implementations, the composite panel 50 may have the same or a similar curing process as the solid laminated girder 100. In other implementations, the composite panel 50 may be formed of the same or similar composite layers 110 or composite plies 400 to reduce material incompatibilities between the composite panel 50 and the solid laminated girder 100, such as thermal cracking and bonding issues.

[0065] As Figure 3 shown, the length L of the solid laminated girder 100 may correspond to the length of the composite panel 50. For example, the length L of the solid laminated girder 100 may extend and / or be equal to the full length of the composite panel 50.

[0066] The length of one or more composite layers 110 can at least correspond to the length of the solid laminated girder 100. For example, at least one of the one or more composite layers 110 can have a length equal to the length of the solid laminated girder 100. In other implementations, the length of all the composite layers 110 is at least equal to the length of the solid laminated girder 100. In yet other implementations, at least one of the one or more composite layers 110 has a length longer than the length of the solid laminated girder 100.

[0067] In some implementations, the length of the composite sheets 400 forming each composite layer 110 is uniform. In other implementations, the length of the composite sheets 400 forming each composite layer 110 varies. For example, the length of the composite sheets 400 can vary along the x-axis (see Figure 5 ).

[0068] The composite layer 110 can be non-jointed. For example, the solid laminated girder 100 can not include a jointed composite layer 110. That is to say, the composite layer 110 can not be formed by one or more composite layers 110 joined together along the length of the solid laminated girder 100. The composite layer 110 can be a single continuous composite layer 110. The composite layer 110 can be a single continuous layer of the composite sheets 400.

[0069] The width of the solid laminated girder 100 can be from about 25 mm to about 150 mm, from about 40 mm to about 130 mm, or from about 50 mm to about 110 mm. For example, the width of the solid laminated girder 100 can be about 60 mm. The width of the solid laminated girder 100 can be uniform along the length L of the girder. In other implementations, the solid laminated girder 100 can have a variable width. For example, as Figure 3 shown, the solid laminated girder 100 can have one or more widths (W1, W2, W3) along the length L of the solid laminated girder 100.

[0070] The width of the solid laminated girder 100 can vary from about 25 mm to about 150 mm along the length L of the solid laminated girder 100. For example, the maximum width of the solid laminated girder can be at least 2 times, 3 times, 4 times, 5 times or 6 times the minimum width of the solid laminated girder 100. In other implementations, the maximum width of the composite layer 110 can be at least 2 times, 3 times or 4 times the minimum width of the composite layer 110.

[0071] The width of the solid laminated girder 100 can vary along at least one of the x-axis and the z-axis. In some implementations, the width of the solid laminated girder can vary along both the x-axis and the z-axis.

[0072] In some implementations, the width of the composite layer 110 forming the solid laminated stringer 100 is uniform along the z-axis. In other implementations, the width of the composite layer 110 forming the solid laminated stringer 100 varies along the z-axis. For example, the width of the solid laminated stringer 100 may be wider at its base where it contacts the composite panel 50 than at the top.

[0073] Thus, as Figure 4 shown, the width of the first composite layer 111 at the base of the solid laminated stringer 100 may be equal to or wider than the width of the second composite layer 112, the third composite layer 113, and / or the fourth composite layer 114. Similarly, the width of the second composite layer 112 may be equal to or wider than the width of the third composite layer 113 and / or the fourth composite layer 114. The width of the third composite layer 113 may also be equal to or wider than the width of the fourth composite layer 114.

[0074] As Figures 3 to 4 shown, the solid laminated stringer 100 may include lateral edges 120. The lateral edges 120 of the solid laminated stringer 100 are formed by the lateral edges of the composite layer 110 forming the solid laminated stringer 100. For example, as Figure 4 shown, the lateral edges 120 are formed by a first lateral edge 121 of the first composite layer 111, a second lateral edge 122 of the second composite layer 112, a third lateral edge 123 of the third composite layer 113, and a fourth lateral edge 124 of the fourth composite layer 114.

[0075] The lateral edges 120 may have an inclination angle ranging from about 12° to about 75°. In other implementations, the lateral edges 120 may have an inclination angle of about 12° to about 18°, about 30° to about 60°, or about 55° to about 72°.

[0076] The inclination angle of the lateral edges 120 may vary along the z-axis. The inclination angle of the lateral edges 120 may vary along at least one of the x-axis, y-axis, and z-axis. In some implementations, the inclination angle of the lateral edges 120 may vary along both the x-axis and the z-axis.

[0077] In some implementations, as Figure 4 shown, the inclination angle of the lateral edges 120 is symmetric. In other implementations, as Figure 4 shown, the first inclination angle of the first lateral edge 121 may be different from the second inclination angle of the second lateral edge 122.

[0078] Compared to the top, the inclination angle of the lateral edges 120 is minimum at its base where it contacts the composite panel 50. Thus, the inclination angle of the lateral edges of the composite layer 110 at the base of the solid laminated stringer 100 may be equal to or less than the inclination angle of the lateral edges of the other composite layers 110 forming the solid laminated stringer.

[0079] For example, as Figure 4 shown, the inclination angle of the first lateral edge 121 of the first composite layer 111 is smaller than the inclination angles of the second lateral edge 122 of the second composite layer 112, the third lateral edge 123 of the third composite layer 113, and the fourth lateral edge 124 of the fourth composite layer 114. Similarly, the inclination angle of the second lateral edge 122 can be smaller than the inclination angles of the third lateral edge 123 and the fourth lateral edge 124.

[0080] In some implementations, the lateral edges 120 are continuous. That is, the lateral edges of the composite layers 110 forming the solid laminated girder 100 form the continuous lateral edges 120 of the solid laminated girder. For example, the first lateral edge 121 can be continuous with the second lateral edge 122, the third lateral edge 123, and the fourth lateral edge 124.

[0081] As Figures 1 to 2 shown, the composite panel 50 can include one or more concave or convex bending portions along at least one of the x-axis, y-axis, and z-axis. Accordingly, the solid laminated girder 100 can include one or more bending portions 600 corresponding to the bending portions of the composite panel 50. The bending portion 600 can be along at least one of the x-axis, y-axis, and z-axis, and the bending portion 600 can be convex or concave. For example, the solid laminated girder can have a bending portion 601 along the y-axis, a bending portion 602 along the x-axis, and / or a bending portion 603 along the z-axis.

[0082] The bending portion 600 along the x-axis can have a bending portion in the x-z plane and / or the x-y plane, and its radius is about 100 inches to about 10 20 inches. For example, the bending portion 602 can have a radius ranging from about 200 inches to about 10 15 inches, from about 400 inches to about 10 10 inches, or from about 800 inches to about 10 5 inches. For example, as Figure 2 shown, the solid laminated girder 100 can have a centerline bending portion 600 along the x-axis in the x-y plane.

[0083] The bending portion 600 along the y-axis in the y-z plane can have a bending portion with a radius of about 20 inches to about 10 20 inches. For example, the bending portion 601 can have a radius of about 100 to about 10 15 inches, about 200 to about 10 10 inches, or about 400 to about 10 5 inches.

[0084] One or more composite layers 110 may include one or more winding layers, and the solid laminated stringer 100 may include one or more winding layers. For example, as Figure 4 shown, the solid laminated stringer 100 may include a base winding layer 155 and a top winding layer 160 as examples of one or more winding layers.

[0085] The top winding layer 160 may be configured to cover the top surface and the lateral edges of the solid laminated stringer 100. For example, as Figure 4 shown, the top winding layer 160 is disposed above the lateral edges 121, 122, 123, and 124 of the first composite layer 111, the second composite layer 112, the third composite layer 113, and the fourth composite layer 114 (forming the lateral edge 120) and above the top surface 130 of the fourth composite layer 114. In some implementations, the top winding layer 160 may cover at least a portion of the composite panel 50. In some implementations, the top winding layer 160 may cover the exposed fiber ends present in the composite layer 110 due to trimming.

[0086] As Figure 4 shown, the base winding layer 155 may be disposed above the top winding layer 160 along the lower portion of the lateral edge 120. The base winding layer 155 may cover at least a portion of the top winding layer 160. The base winding may also be disposed above at least a portion of the composite panel 50. The base winding layer 155 may cover at least a portion of the composite panel 50. In some implementations, the bottom winding layer 155 enhances the connection of the solid laminated stringer 100 to the composite panel 50 to prevent delamination.

[0087] As described above, the length of the composite sheet layer 400 forming each composite layer 110 may vary. Figure 5 Shows a longitudinal stacking configuration of the composite layers forming a solid laminated stringer according to one implementation.

[0088] As Figure 5 shown, the lengths of the composite sheet layers 400 forming the second composite layer 112 and the third composite layer 113 may vary along the x-axis along the axis of symmetry 606. For example, the lengths of the composite sheet layers 400 forming the second composite layer 112 and the third composite layer 113 may successively terminate along the x-axis around the axis of symmetry 606. The lengths of the composite sheet layers 400 forming the first composite layer 111 and the fourth composite layer 114 may be uniform and may at least correspond to the length L of the solid laminated stringer 100 and / or the length of the composite panel 50.

[0089] Figure 6 Shows a transition end of a solid laminated stringer according to one implementation. Figure 7 Shows a longitudinal cross-sectional view of a transition end of a solid laminated stringer according to one implementation. As Figures 6 to 7As shown above, regarding Figure 5 The approximate symmetric arrangement of the composite sheets in the composite layer 110 described above can be advantageous at the transition end of the solid laminated girder 100. For example, when the composite sheets 400 of the second composite layer 112 and the third composite layer 113 terminate successively, the height (along the z-axis) of the solid laminated girder 100 can decrease along the x-axis. The alternating termination of the composite sheets 400 from directly above the axis of symmetry 606 to directly below the axis of symmetry 606 can help maintain the approximate symmetry of the remaining composite sheets 400 that form the composite layer 110.

[0090] For the purpose of showing the stepped configuration of the successively terminated composite sheets 400, Figure 5 the schematic diagram shown in does not show the remaining composite sheets 400 converging at the axis of symmetry 606, and thus reduces the height of the solid laminated girder 100 once formed. However, this effect is shown in Figures 6 to 7 shown in.

[0091] As Figures 6 to 7 shown, when the composite sheets 400 of the second composite layer 112 and the third composite layer 113 terminate successively along the axis of symmetry 606, the height of the solid laminated girder 100 decreases along the x-axis towards the transition end 605. The transition end 605 can correspond to the total length of the solid laminated girder 100 and / or can correspond to the total length of the composite panel 50. As Figure 6 shown, the width of the solid laminated girder 100 can increase as the height decreases towards the transition end 605. In addition, the first composite layer 111 and the fourth composite layer 114 remain as the lowermost and uppermost composite layers 110 of the solid laminated girder 100. The longitudinal cross-sectional view in the x-z plane shown in Figure 7 shows the fourth composite layer 114 and the first composite layer 111 converging to the axis of symmetry 606 at the transition end 605. A top wrap layer 160 (not shown) can be provided above the fourth composite layer 114.

[0092] Figures 8 to 9 shows a system for forming a solid laminated girder on a composite panel according to one implementation. As Figure 8 shown, the system 700 for forming a solid laminated girder 100 on a composite panel 50 includes a reel 710, a cutter 720, a roller 730, and a computer 740.

[0093] Figure 10 shows a method for forming a solid laminated girder on a composite panel according to one implementation. Figure 10 shows, for example, an example of a method that can be used to manufacture the solid laminated girder 100 as described above and as Figures 1 to 7 shown. As Figure 10 shown, reference can be made to Figure 8 the system 700 andFigures 1 to 7 A method 800 for forming a solid laminated stringer 100 on a composite panel 50 will be described with respect to the solid laminated stringer.

[0094] It should be understood that for this and other processes and methods disclosed herein, Figure 10 and Figure 12 the method shows the functions and operations of one or more possible implementations of the present disclosure. In this regard, Figure 10 and Figure 12 each block in the method may represent a module, segment, or portion of program code that includes one or more instructions executable by a processor to implement or cause a specific logical function or step in the process. For example, Figure 10 and Figure 12 the method can be implemented by one or more computing devices of a robotic assembly system. Those skilled in the art should understand that alternative implementations are included within the scope of the implementations of the present disclosure, where the functions may be performed not in the order shown or discussed, including substantially simultaneously, depending on the functions involved.

[0095] Method 800 may begin with operation 801. Operation 801 includes unwinding one or more composite layers 110 onto the composite panel 50.

[0096] One or more composite layers 110 may be continuously unwound along a length corresponding to the length of the solid laminated stringer 100. As used herein, the term "continuously unwind" means unwinding the composite layer 110 into a single continuous composite layer 110. The continuously unwound composite layer 110 is not spliced. That is, the continuously unwound composite layer 110 is not formed by one or more composite layers 110 spliced together along a length corresponding to the length of the solid laminated stringer 100.

[0097] As Figure 8 shown, the reel 710 may be configured to hold one or more composite layers 110. The reel 710 may be configured to deposit one or more composite layers 110 onto the composite panel 50. For example, the reel 710 may be part of a robotic assembly that is configured to move above the composite panel 50 and deposit one or more composite layers 110 from the reel 710 onto the composite panel 50 by unwinding the reel 710.

[0098] Unwinding one or more composite layers 110 onto the composite panel 50 may include aligning the edges and / or centerlines of one or more composite layers 110 in a preset stacking order when unwound onto the composite panel 50. For example, the edges of one or more composite layers 110 may be aligned using overhead laser projection when unwound onto the composite panel 50. In one implementation, a reel 710 (or a larger robotic assembly) configured to move and rotate over the composite panel 50 includes one or more laser receivers configured to receive a continuous laser beam from an overhead laser projector (OLP). The angle and distance to the OLP are automatically calculated by a processor in the reel 710. Then, the calculated angle and distance information may be compared with a map or layout corresponding to a predefined solid laminated girder 100 to determine the position of the target position of the one or more composite layers 110 being unwound by the reel 710 relative to the predefined solid laminated girder 100. Then, the reel 710 may be guided and moved while adjusting the speed, rotation rate, compaction pressure, heating temperature, etc. based on flow data according to deposition width / thickness and surface bend requirements to align the edges or positions of one or more composite layers 110 when unwound onto the composite panel 50 in a preset stacking order and / or onto one or more composite layers 110 that have already partially formed the solid laminated girder 100 on the composite panel 50.

[0099] Thus, unwinding one or more composite layers 110 onto the composite panel 50 may include using overhead laser projection of the target position to align the edges and / or centerlines of one or more composite layers 110 on the composite panel 50 in a preset order.

[0100] For example, as Figure 8 shown, the first composite layer 111 may be deposited onto the composite panel 50 by unwinding the first composite layer 111 from the reel 710. The reel 710 may use overhead laser projection to align the front edge 613 of the first composite layer 111 to correspond to the composite panel 50. For example, the reel 710 may start depositing the first composite layer 111 at the front edge 51 of the composite panel 50.

[0101] As Figure 9 shown, in some implementations, the system 700 may include one or more reels 710, and the one or more reels 710 may be configured to simultaneously deposit one or more composite layers 110 onto the composite panel 50 to form one or more solid laminated girders 100.

[0102] In some implementations, the computer 740 is used to guide and control the reel 710 to move along a preset path line at a predefined speed or rate. The path line may include nearly straight and / or slight bends 600 (see Figure 2)。For example, the computer 740 can be used to store mappings or layouts corresponding to the solid laminated girder 100, pre-set slightly curved path lines, pre-determined moving speeds, rotation rates, compaction pressures, heating temperatures, etc., stacking sequences or indexes, layout orders, pre-defined geometric positions of edge lines and center lines, pre-calculated widths of one or more composite layers 110, bends and lengths or designs, and the overall geometry or shape of the solid laminated girder. In one implementation, the computer 740 stores the lengths of one or more composite layers 110 corresponding to the length of the solid laminated girder 100. The computer 740 can be used to guide and move the reel 710 along a pre-set path line at a pre-determined moving speed, rotation rate, compaction pressure, and heating temperature according to the sequentially executed unwinding command steps and the above-stored information.

[0103] Thus, in some implementations, unwinding one or more composite layers 110 onto the composite panel 50 includes synchronously unwinding one or more composite layers 110 using overhead laser projection according to at least one of the moving speed, rotation rate, compaction pressure, and heating temperature. Unwinding one or more composite layers 110 onto the composite panel 50 can align the edges of one or more composite layers 110 on the composite panel 50 to the bend 600. Unwinding one or more composite layers 110 onto the composite panel 50 can include using the computer 740 to control the reel 710 to perform unwinding along a pre-set nearly straight and / or slightly curved bend 600 according to at least one of the pre-determined moving speed, rotation rate, compaction pressure, and heating temperature.

[0104] Operation 802 includes compacting one or more composite layers 110 unwound onto the composite panel 50.

[0105] As Figure 8 shown, the system 700 can include a compaction roller 730. The compaction roller 730 can be configured to compact the composite layer 110 unwound onto the composite panel 50 and / or the composite layer 110 unwound onto other composite layers 110 that have already partially formed the solid laminated girder 100 on the composite panel 50. The compaction roller 730 can be configured to apply pressure and / or heating temperature to the unwound composite layer 110.

[0106] Operation 803 includes cutting one or more composite layers 110 unwound onto the composite panel 50.

[0107] As Figure 8 shown, the system 700 can include a cutter 720. The cutter 720 can be configured to cut the composite layer 110 unwound onto the composite panel 50 and / or the composite layer 110 unwound onto other composite layers 110 that have already partially formed the solid laminated girder 100 on the composite panel 50.

[0108] In operation 803, cutter 720 cuts composite layer 110 into a desired length. For example, as Figure 10 shown, cutter 720 can cut first composite layer 111 into a length corresponding to the length of solid laminated stringer 100 and / or composite panel 50. The length of first composite layer 111 can correspond to the full length of solid laminated stringer 100 and / or composite panel 50.

[0109] In some implementations, one or more composite layers 110 are continuous within reel 710. That is, composite layer 110 can include first composite layer 111, second composite layer 112, third composite layer 113, and / or fourth composite layer 114 as continuous composite layer 110. Cutting first composite layer 111 exposes the leading edge (not shown) of second composite layer 112. When depositing second composite layer 112, reel 710 can then align the leading edge of second composite layer 112 with the leading edge 613 of first composite layer 111 or the leading edge 51 of composite panel 50. However, in other implementations, as Figure 9 shown, reel 710 can include one or more reels 710, and each reel 710 can include composite layer 110. For example, one or more reels 710 can include first composite layer 111, second composite layer 112, third composite layer 113, and / or fourth composite layer 114, and one or more reels 710 can work together in sequence to deposit solid laminated stringer 100 onto composite panel 50.

[0110] Although the above operations are described with respect to first composite layer 111, it should be understood that other composite layers 110 can be similarly unwound, compacted, and cut onto composite panel 50, including second composite layer 112, third composite layer 113, fourth composite layer 114, as well as base wrap layer 155 and top wrap layer 160, as Figure 4 shown.

[0111] Operation 804 includes curing one or more composite layers 110 that are unwound and compacted onto composite panel 50.

[0112] Curing one or more composite layers 110 can include applying heat and pressure to one or more composite layers 110. For example, curing can include using an autoclave under heat and pressure treatment conditions corresponding to the materials of one or more composite layers 110 and / or composite panel 50.

[0113] As Figure 4As shown, operation 804 may include placing a vacuum bag 300 over one or more composite layers 110 that form the solid laminated stringer 100 and the composite panel 50. In some implementations, the vacuum bag 300 covers at least a portion of the composite panel 50. The vacuum bag 300 may be used to apply a compaction pressure to one or more composite layers 110 prior to and during curing under operation 804. Thus, in some implementations, curing the one or more composite layers 110 onto the composite panel 50 includes placing the vacuum bag 300 over the one or more composite layers 110 and applying a compaction pressure to the one or more composite layers 110.

[0114] In some implementations, operation 804 includes simultaneously curing the one or more composite layers 110 that form the solid laminated stringer 100 and curing the composite panel 50. Thus, the vacuum bag 300 may cover at least a portion of the composite panel 50, and curing the one or more composite layers 110 onto the composite panel 50 may include simultaneously curing the composite panel 50.

[0115] Figure 11 A system for winding composite layers according to one implementation is shown. As Figure 11 shown, the system 701 for winding composite layers 110 includes a reel 710, one or more cutters 750, one or more rollers 760, a forming table 770, and a computer 740.

[0116] Figure 12 A method for winding composite layers according to one implementation is shown. Figure 12 An example of a method that may be used to wind composite layers 110 as described above and as Figures 1 to 7 shown is presented. As Figure 12 shown, the method 900 for winding composite layers may be described with respect to Figure 11 the system 701 and Figures 1 to 7 the composite layers 110.

[0117] The method 900 may begin with placing one or more composite sheets on the forming table in operation 906. As Figure 11 shown, one or more composite sheets 400 may be placed on the forming table 770 as part of forming the composite layers 110. The one or more composite sheets 400 may be placed on the forming table 770 via automated fiber placement (AFP) or automated tape laying (ATL). In some implementations, operation 906 includes applying a vacuum to the one or more composite sheets 400 through the forming table 770 to hold them in place.

[0118] One or more composite plies may be placed continuously along the length of the forming table. As used herein, the term "placed continuously" means placing the composite ply 400 as a single continuous composite ply 400. The continuously placed composite ply 400 is not spliced. That is, the continuously placed composite ply 400 is not formed by one or more composite plies 400 spliced together along the length of the forming table.

[0119] Operation 906 may include placing one or more composite plies 400 according to a specific orientation layup. The orientation layup may be stored in the computer 740 and may be used to control the AFP and / or ATL machine to form the composite layer 110.

[0120] Operation 907 includes trimming one or more composite plies placed on the forming table. As Figure 11 shown, one or more cutters 750 may be used to trim one or more composite plies 400 placed on the forming table 770. One or more cutters 750 may include ultrasonic cutters 750.

[0121] One or more cutters 750 may be used to define the width of one or more composite plies 400 placed on the forming table 770 and / or the resulting composite layer 110. The width may be uniform, or as Figure 11 shown, the width may include one or more widths (W1, W2, W3) along the length of one or more composite plies 400.

[0122] One or more cutters 750 may be used to define the lateral edges of one or more composite plies 400 placed on the forming table 770 and / or the resulting composite layer 110. The lateral edges may be uniform, or as Figure 4 shown, the lateral edges may have an inclination angle between 12° and 75°.

[0123] One or more cutters 750 may be used to define the shape of one or more composite plies 400 placed on the forming table 770 and / or the resulting composite layer 110. The shape may be substantially symmetric. For example, the two lateral edges may be at the same distance from the layer centerline along the longitudinal direction by about half the layer width and may have about the same inclination angle.

[0124] One or more cutters 750 may be used to define the length of one or more composite plies 400 placed on the forming table 770 and / or the resulting composite layer 110. The length may correspond to the length of the solid laminated stringer 100 and / or the composite panel 50. In other implementations, the length of one or more composite plies 400 may correspond to the transition end of the solid laminated stringer 100.

[0125] Operation 908 includes compressing one or more composite plies 400 placed on a forming table. As Figure 11 shown, system 701 may include one or more rollers 760. One or more rollers 760 may be configured to compress one or more composite plies 400 placed on forming table 770 into composite layer 110.

[0126] In some implementations, when compressing in operation 908, one or more rollers 760 apply or maintain tension to one or more composite plies 400. Compressing or tensioning one or more composite plies 400 can reduce wrinkling when winding the resulting composite layer 110.

[0127] In some implementations, one or more rollers 760 prevent ply wrinkling and expel remaining air gaps within and between composite plies 400 to reduce ply distortion or defects. One or more rollers 760 may also generate tension to straighten composite plies 400, thereby preventing wrinkling and slippage when winding the resulting composite layer 110.

[0128] Operation 909 includes winding one or more composite plies 400 that have been compressed into composite layer 110 onto a reel 710. As Figure 11 shown, composite layer 110 (produced by compressing and tensioning composite plies 400) is wound onto reel 710. One or more composite layers 110 may include wound prepregs.

[0129] Operation 909 may include heating and cooling one or more compressed composite plies 400. For example, to reduce wrinkling of one or more composite plies 400 that are compressed into composite layer 110 during winding, one or more composite plies 400 may first be heated during or after the compaction operation 908. Similarly, to reduce tackiness, one or more composite plies 400 may be cooled during or before the winding operation 909.

[0130] Composite layer 110 produced by compressing one or more composite plies 400 may include prepregs.

[0131] Composite layer 110 wound on reel 710 may include a continuous composite layer 110 that includes one or more composite plies 400.

[0132] Composite layer 110 produced by compressing one or more composite plies 400 may include variable widths and bends to correspond to the width or bends of solid laminated stringer 100.

[0133] In some implementations, the computer 740 stores a laying design for the solid laminated stringer 100, and the composite layer 110 is wound onto the reel 710 to correspond to the shape, curve, and geometry of the desired solid laminated stringer 100. In other implementations, one or more composite layers 110 are wound onto one or more reels 710, and the computer 740 controls the laying of one or more composite layers 110 through one or more reels 710 to form the solid laminated stringer 100 on the composite panel 50. Thus, in some implementations, the composite layer 110 is wound according to the laying design for the solid laminated stringer 100.

[0134] Implementations of the present disclosure may find use in a variety of potential applications, particularly in the transportation industry, including, for example, aerospace, marine, automotive applications, and other applications that require solid laminated stringers. Thus, reference is now made to Figure 13 and Figure 14 , implementations of the present disclosure can be used in the context of an aircraft manufacturing and maintenance method 1000 as shown in Figure 13 and an aircraft 2000 as shown in Figure 14 . During pre-production, the exemplary method 1000 may include the specification and design 1102 of the aircraft 2000 and the material procurement 1104. During production, the manufacture 1106 of the components and sub-assemblies of the aircraft 2000 and the system integration 1108 occur. Thereafter, the aircraft 2000 may undergo certification and delivery 1110 in order to be put into service 1112. When in service by a customer, the aircraft 2000 is scheduled for routine maintenance and repair 1114, which may also include modifications, reconstructions, overhauls, etc.

[0135] Each process of the method 1000 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). For the purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and prime system subcontractors; a third party may include, but is not limited to, any number of suppliers, subcontractors, and vendors; and an operator may be an airline, a leasing company, a military entity, a maintenance organization, etc.

[0136] As shown in Figure 14 , the aircraft 2000 produced by the exemplary method 1000 may include a fuselage 2115 and an interior 2120 having a plurality of systems 2118. Examples of the systems 2118 include one or more of a propulsion system 2122, an electrical system 2124, a hydraulic system 2126, and an environmental system 2128. Any number of other systems may be included. Although an aerospace example is shown, the principles of the present disclosure may be applied to other industries, such as the marine and automotive industries.

[0137] During any one or more stages of an aircraft manufacturing and repair method 1000, the systems and methods illustrated herein may be employed. For example, components or sub-components corresponding to the production process 1106 may be manufactured or produced in a manner similar to components or sub-components produced when the aircraft 2000 is in service. Moreover, during the production stages 1106 and 1108, one or more device examples, method examples, or combinations thereof may be utilized, such as by sufficiently accelerating the assembly of the aircraft 2000 or reducing its cost. Similarly, when the aircraft 2000 is in service, such as but not limited to, maintenance and repair 1114, one or more device examples, method examples, or combinations thereof may be utilized.

[0138] While Figure 13 and Figure 14 the disclosure has been described with respect to aircraft and aircraft manufacturing and repair, the disclosure is not limited thereto. The solid laminated stringer systems and methods of the present disclosure may also be used for spacecraft, satellites, submarines, surface ships, automobiles, tanks, trucks, power equipment, and any other suitable type of object.

[0139] The present disclosure includes example embodiments in accordance with the following clauses:

[0140] Clause 1. A method (800, 900) of manufacturing a solid laminated stringer (100) on a composite panel (50), the method comprising:

[0141] Unwinding one or more composite layers (110) onto the composite panel (50);

[0142] Compacting the one or more composite layers (110) unwound onto the composite panel (50);

[0143] Cutting the one or more composite layers (110) unwound onto the composite panel (50); and

[0144] Curing the one or more composite layers (110) unwound onto the composite panel (50).

[0145] Clause 2. The method (800, 900) of clause 1, wherein unwinding the one or more composite layers (110) onto the composite panel (50) includes synchronizing the unwinding of the one or more composite layers (110) using an overhead laser projection based on at least one of a moving speed, a rotation rate, a compaction pressure, and a heating temperature.

[0146] Clause 3. The method (800, 900, 1000) according to Clause 2, wherein unwinding the one or more composite layers (110) onto the composite panel (50) includes aligning at least one of an edge and a centerline of the one or more composite layers (110) on the composite panel (50) to a curved line (600).

[0147] Clause 4. The method (800, 900) according to any one of Clauses 1 to 3, wherein unwinding the one or more composite layers (110) onto the composite panel (50) includes performing the unwinding along a predefined substantially straight and slightly curved line (600) using a computer (740)-controlled reel (710) according to at least one of a predefined moving speed, rotation rate, compaction pressure, and heating temperature.

[0148] Clause 5. The method (800, 900) according to any one of Clauses 1 to 4, wherein curing the one or more composite layers (110) unwound onto the composite panel (50) includes placing a vacuum bag (300) over the one or more composite layers (110) and applying a compaction pressure to the one or more composite layers (110).

[0149] Clause 6. The method (800, 900) according to Clause 5, wherein the vacuum bag (300) covers at least a portion of the composite panel (50), and wherein curing the one or more composite layers (110) unwound onto the composite panel (50) includes curing the composite panel (50) simultaneously.

[0150] Clause 7. The method (800, 900) according to any one of Clauses 1 to 6, wherein the solid laminated girder (100) includes two or more composite layers (110), and

[0151] wherein each of the one or more composite layers (110) includes one or more composite plies (400).

[0152] Clause 8. The method (800, 900) according to any one of Clauses 1 to 7, wherein the one or more composite layers (110) are specifically wound prepregs.

[0153] Clause 9. The method (800, 900) according to Clause 8, wherein each of the one or more composite layers (110) is wound according to a laying design for the solid laminated girder (100), and

[0154] wherein the length of the one or more composite layers (110) corresponds at least to the length of the solid laminated girder (100).

[0155] Clause 10. The method (800, 900) according to any one of Clauses 1 to 9, wherein the solid laminated stringer (100) does not include a spliced composite layer (110).

[0156] Clause 11. The method (800, 900) according to any one of Clauses 1 to 10, wherein the solid laminated stringer (100) has a width of from about 25 mm to about 150 mm.

[0157] Clause 12. The method (800, 900) according to any one of Clauses 1 to 11, wherein the solid laminated stringer (100) includes one or more transverse edges (120), and wherein the one or more transverse edges (120) include an inclination angle of from about 12° to about 75°.

[0158] Clause 13. The method (800, 900) according to any one of Clauses 1 to 12, wherein the solid laminated stringer (100) includes one or more concave or convex bending portions (601, 602, 603) along at least one of the x-axis, y-axis, and z-axis.

[0159] Clause 14. The method (800, 900) according to Clause 13, wherein the bending portion (601, 602, 603) along the x-axis has a radius of from about 100 inches to about 10 20 inches.

[0160] Clause 15. The method (800, 900) according to Clause 13, wherein the bending portion (601, 602, 603) along the y-axis has a radius of from about 20 inches to about 10 20 inches.

[0161] Clause 16. The method (800, 900) according to any one of Clauses 1 to 15, wherein the one or more composite layers (110) include at least one of a base winding layer (155) and a top winding layer (160).

[0162] Clause 17. A method (800, 900) for winding a composite layer (110), the method comprising:

[0163] Placing one or more composite sheets (400) on a forming table (770);

[0164] Trimming the one or more composite sheets (400) placed on the forming table (770);

[0165] Compacting the one or more composite sheets (400) placed on the forming table (770); and

[0166] Wind the compacted one or more composite plies (400) onto a reel (710).

[0167] Clause 18. The method (800, 900) according to clause 17, wherein placing the one or more composite plies (400) onto a forming table (770) comprises:

[0168] Placing the one or more composite plies (400) via automated fiber placement (AFP) or automated tape laying (ATL).

[0169] Clause 19. The method (800, 900) according to clause 17 or 18, wherein trimming the one or more composite plies (400) placed on the forming table (770) comprises at least one of the following:

[0170] Trimming the one or more composite plies (400) to define a composite layer (110) having two or more widths;

[0171] Trimming the one or more composite plies (400) to define a composite layer (110) having a lateral edge (120) with an inclination angle between 12° and 75°;

[0172] Trimming the one or more composite plies (400) to define a composite layer (110) having a substantially symmetric lateral edge (120); and

[0173] Trimming the one or more composite plies (400) to define the length of the composite layer (110).

[0174] Clause 20. The method (800, 900) according to any one of clauses 17 to 19, wherein the compacted one or more composite plies (400) form a prepreg composite layer (110), and wherein winding the compacted one or more composite plies (400) onto a reel (710) comprises winding the prepreg composite layer (110) according to a laying design for a solid laminated longitudinal beam (100).

[0175] The present disclosure has been described with reference to exemplary implementations. Although some implementations have been shown and described, those skilled in the art will understand that changes can be made to these implementations without departing from the principles and spirit of the foregoing detailed description. The present disclosure is intended to be construed to include all such modifications and changes as long as they fall within the scope of the appended claims or their equivalents.

Claims

1. A method (800, 900) for manufacturing a solid laminated girder (100) on a composite panel (50), the method comprising: Unwinding one or more composite layers (110) onto the composite panel (50), including aligning at least one of an edge and a centerline of the one or more composite layers (110) on the composite panel (50) to one or more curved lines (600), and wherein the one or more composite layers (110) are continuously unwound along a length corresponding to the length of the solid laminated girder (100); Compacting the one or more composite layers (110) unwound onto the composite panel (50); Cutting the one or more composite layers (110) unwound onto the composite panel (50); and Curing the one or more composite layers (110) unwound onto the composite panel (50).

2. The method (800, 900) according to claim 1, wherein, Unwinding the one or more composite layers (110) onto the composite panel (50) includes synchronizing the unwinding of the one or more composite layers (110) using an overhead laser projection according to at least one of a moving speed, a rotation rate, a compaction pressure, and a heating temperature.

3. The method (800, 900) according to claim 2, wherein, One or more of the one or more curved lines (600) correspond to a bent portion of the composite panel (50).

4. The method (800, 900) according to any one of claims 1 to 3, wherein Unwinding the one or more composite layers (110) onto the composite panel (50) includes performing the unwinding along a pre-set substantially straight and slightly curved line (600) using a computer (740)-controlled reel (710) according to at least one of a pre-determined moving speed, a rotation rate, a compaction pressure, and a heating temperature.

5. The method (800, 900) according to any one of claims 1 to 3, wherein, Curing the one or more composite layers (110) unwound onto the composite panel (50) includes placing a vacuum bag (300) over the one or more composite layers (110) and applying a compaction pressure to the one or more composite layers (110).

6. The method (800, 900) according to claim 5, wherein, The vacuum bag (300) covers at least a portion of the composite panel (50), and wherein curing the one or more composite layers (110) unwound onto the composite panel (50) includes curing the composite panel (50) simultaneously.

7. The method (800, 900) according to any one of claims 1 to 3, wherein, The solid laminated girder (100) includes two or more composite layers (110), and wherein each of the one or more composite layers (110) includes one or more composite plies (400).

8. The method (800, 900) according to any one of claims 1 to 3, wherein The one or more composite layers (110) are specifically wound prepregs.

9. The method (800, 900) according to claim 8, wherein, Each of the one or more composite layers (110) is wound according to a laying design for the solid laminated girder (100), and wherein the length of the one or more composite layers (110) corresponds at least to the length of the solid laminated girder (100).

10. The method (800, 900) according to any one of claims 1 to 3, wherein, The solid laminated girder (100) does not include spliced composite layers.

11. The method (800, 900) according to any one of claims 1 to 3, wherein, The width of the solid laminated girder (100) is 25 mm to 150 mm.

12. The method (800, 900) according to any one of claims 1 to 3, wherein, The solid laminated longitudinal beam (100) includes one or more transverse edges (120), and wherein the one or more transverse edges (120) include an inclination angle of 12° to 75°.

13. The method (800, 900) according to any one of claims 1 to 3, wherein, The solid laminated longitudinal beam (100) includes one or more concave or convex bending portions (601, 602, 603) along at least one of the x-axis, y-axis, and z-axis.

14. The method (800, 900) according to claim 13, wherein, The bending portions (601, 602, 603) along the x-axis have a radius ranging from 100 inches to 10 20 inches.

15. The method (800, 900) according to claim 13, wherein, The curved portions (601, 602, 603) along the y-axis have a radius ranging from 20 inches to 10 20 inches.

16. The method (800, 900) according to any one of claims 1 to 3, wherein, The one or more composite layers (110) include at least one of a base winding layer (155) and a top winding layer (160).

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