Bead composite structure and method for manufacturing a bead composite structure

Abstract

A composite structure having a first layer connected to a second layer to form a layered structure. The second layer has a plurality of bases abutting the first layer and a plurality of beads projecting from the plurality of bases. Each bead of the plurality of beads defines a channel between the first layer and the second layer. A method for manufacturing a composite structure includes depositing a composite material on a tool to form a second layer. The second layer has a plurality of beads and a plurality of bases. The method includes distributing a plurality of mandrels on the second layer to define channels in the plurality of beads. The method includes depositing a composite material on the second layer and the plurality of mandrels to form a first layer. The method includes bonding the first layer to the second layer.

Description

Technical Field

[0001] This application relates to a composite structure, and more specifically, to a composite structure and a method for manufacturing the composite structure. Background Technology

[0002] Typical architectural designs for aircraft wing components require the fabrication of individual blade stringers and vent stringers before bonding or co-curing. These individual fabrication steps are both expensive and time-consuming. Furthermore, typical architectural designs for aircraft wings require numerous components, which increase the overall structural weight. Moreover, the space between the upper and lower sections of an aircraft wing is often limited and difficult to maneuver during initial assembly and subsequent maintenance. Access to this space is restricted once the aircraft wing has been assembled.

[0003] Therefore, those skilled in the art continue to conduct research and development in the field of manufacturing composite structures. Summary of the Invention

[0004] The bead-like composite structure was disclosed.

[0005] In one or more embodiments, the disclosed composite structure includes a first layer and a second layer connected to the first layer to form a layered structure. The second layer has a plurality of bases adjacent to the first layer and a plurality of bead-like portions projecting from the plurality of bases. Each of the plurality of bead-like portions defines a channel between the first layer and the second layer.

[0006] A method for manufacturing bead-like composite structures was also disclosed.

[0007] In one or more instances, the disclosed method for manufacturing a composite structure includes depositing a composite material on a tool to form a second layer. The second layer has a plurality of bead-like portions and a plurality of base portions. The method further includes distributing a plurality of mandrels on the second layer to define channels within the plurality of bead-like portions. The method also includes depositing the composite material on the second layer and the plurality of mandrels to form a first layer. The method further includes bonding the first layer to the second layer.

[0008] Other examples of the beaded composite structures and methods for manufacturing beaded composite structures will become apparent from the following detailed description, accompanying drawings and appended claims. Attached Figure Description

[0009] Figure 1 This is a perspective view of the composite structure;

[0010] Figure 2A This is a perspective view of the beaded portion of the composite structure;

[0011] Figure 2B yes Figure 1 A perspective view of the beaded portion of the composite structure;

[0012] Figure 3A It is a top-down plan view of the aircraft's wings;

[0013] Figure 3B yes Figure 3A A perspective view of the beaded portion of the wing;

[0014] Figure 4 yes Figure 1 A perspective view of a portion of the composite structure;

[0015] Figure 5A It is used for manufacturing Figure 1 A flowchart of the method for constructing a composite structure;

[0016] Figure 5B yes Figure 5A A flowchart of a part of the method;

[0017] Figure 5C yes Figure 5A A flowchart of a part of the method;

[0018] Figure 6 This is a perspective view of the composite structure;

[0019] Figure 7 It is a flowchart of aircraft production and maintenance methods; and

[0020] Figure 8 This is a schematic diagram of an airplane. Detailed Implementation

[0021] In the following description, numerous specific details are set forth to provide a thorough understanding of the concepts of this disclosure, which may be practiced without some or all of these details. In other instances, details of known apparatuses and / or processes have been omitted to avoid unnecessarily obscuring this disclosure. While some concepts will be described in conjunction with specific examples, it should be understood that these examples are not intended to be limiting.

[0022] Unless otherwise stated, the terms “first,” “second,” etc., are used merely as labels in this document and are not intended to impose any order, position, or hierarchy on the items referred to by these terms. Furthermore, references to terms such as “second” do not require or exclude the existence of terms such as “first” or lower numbered terms, and / or terms such as “third” or higher numbered terms.

[0023] The reference to "one or more instances" here means that one or more features, structures, or characteristics described in connection with an instance are included in at least one implementation. The phrase "one or more instances" in different places in the specification may or may not refer to the same instance.

[0024] As used herein, a system, apparatus, structure, article, element, component, or hardware "configured" to perform a specified function is one that is genuinely capable of performing the specified function without any changes, and not merely has the potential to perform the specified function only after further modification. In other words, a system, apparatus, structure, article, element, component, or hardware "configured" to perform a specified function is deliberately selected, created, implemented, utilized, programmed, and / or designed to achieve the purpose of performing the specified function. As used herein, "configured" means the existing features of a system, apparatus, structure, article, element, component, or hardware that enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as "configured" to perform a particular function may additionally or alternatively be described as being "suitable" and / or "operable" to perform that function.

[0025] The following are illustrative and non-exhaustive examples of the topics discussed in this article.

[0026] Figure 1 A perspective view of a composite structure 100 including a first layer 110 and a second layer 120 is shown. The first layer 110 is connected to the second layer 120 to form a layered structure 105. Although the composite structure 100 is in Figure 1 The diagram shows the skin panel of an aircraft wing, but those skilled in the art will understand that the disclosed composite structure 100 can be used in a variety of applications, including a variety of non-aerospace applications.

[0027] In one or more instances, the second layer 120 of the composite structure 100 includes a plurality of bases 140 and a plurality of bead-like portions 130. The plurality of bases 140 may be adjacent to the first layer 110 within the layered structure 105 of the composite structure 100. The plurality of bead-like portions 130 may protrude from the plurality of bases 140. Thus, each of the plurality of bead-like portions 130 defines an associated channel 135 between the first layer 110 and the second layer 120, such that the composite structure 100 includes a plurality of channels 135.

[0028] In one or more instances, at least one system feature 300 may be disposed in at least one of a plurality of channels 135. The system feature 300 may be, for example, a wire 310, a conduit 320, a cable, a pipe, an optical fiber, etc. Various other system features 300 may be received within the plurality of channels 135 without departing from the scope of this disclosure.

[0029] In one or more instances, the second layer 120 of the composite structure 100 may be formed of or may include a composite material. The composite material of the second layer 120 may include a reinforcing material encapsulated within a polymer matrix material. As a particular non-limiting example, the reinforcing material may be (or may include) carbon fiber, glass fiber, etc., while the polymer matrix material may be (or may include) a thermosetting (e.g., epoxy) resin. Various thermoplastic resins, such as polyaryletherketone, may also be considered.

[0030] In one or more instances, the layered structure 105 of the composite structure 100 defines one or more access holes 150. In one variation, the access hole 150 extends through both the first layer 110 and the second layer 120. In another variation, the access hole 150 extends only through the first layer 110 of the layered structure 105. In yet another variation, the access hole 150 extends only through the second layer 120 of the layered structure 105. Thus, the access hole 150 may be located in one of the multiple beaded portions 130. Figure 6 ), on one of the multiple bases 140, or the composite structure 100 includes more than one access hole 150, wherein at least one access hole 150 is located in the beaded portion 130 and at least one access hole 150 is located on the base 140.

[0031] Figure 6 At least one access hole 150 shown allows access to one of the plurality of beaded portions 130 for maintenance. One or more system features 300 may be located in one of the plurality of beaded portions 130. The access hole 150 allows one or more system features 300 to extend to the outside of the beaded portion 130.

[0032] like Figure 1 As shown, in one or more instances, the composite structure 100 may further include an access cover 151 that seals at least one access hole 150. Figure 1 The access hatch cover 151 may be fluid-tight, thereby preventing fluid from passing through the associated access hatch 150. The access hatch cover 151 (fuel dam) is configured to be easily accessible from outside the aircraft wing 170 for inspection and maintenance, thereby reducing the need for access to confined spaces.

[0033] In one or more instances, the first layer 110 of the composite structure 100 does not have beaded portions 130. Alternatively, although not shown in the figures, the first layer 110 may include a plurality of beaded portions 130 and a plurality of base portions 140, similar to the second layer 120.

[0034] In one or more instances, the first layer 110 of the composite structure 100 may be formed of or may include a composite material. The composite material of the first layer 110 may include a reinforcing material encapsulated within a polymer matrix material. As a particular non-limiting example, the reinforcing material may be (or may include) carbon fiber, glass fiber, etc., while the polymer matrix material may be (or may include) a thermosetting (e.g., epoxy) resin. Various thermoplastic resins, such as polyaryletherketone, may also be considered.

[0035] As attached Figure 2A and 2B As best illustrated, in one or more instances, the first layer 110 may define an access hole 150, thereby providing a passage 135 between the first layer 110 and the second layer 120. Figure 1 The composite structure 100 may include an entry point for multiple channels 135. Those skilled in the art will understand that the composite structure 100 may include providing access to multiple channels 135. Figure 1 ) has one or more access ports 150.

[0036] Figure 2A and Figure 2B Two examples of multiple bead-like portions 130 are shown. Specifically, Figure 2A The diagram shows a beaded portion 130 with a cross-section roughly cap-shaped, while... Figure 2B The bead-shaped portion 130 with a roughly circular cross-section is shown.

[0037] like Figure 2A As shown, each of the plurality of bead-like portions 130 may include opposing sidewall portions 132 and a cover portion 134 extending between the sidewall portions 132. In one or more embodiments, the plurality of base portions 140 have a first nominal cross-sectional thickness T1, the sidewall portions 132 have a second nominal cross-sectional thickness T2, and the cover portion 134 has a third nominal cross-sectional thickness T3. In one or more embodiments, the third nominal cross-sectional thickness T3 is greater than (e.g., at least 5%, such as at least 20%) the first nominal cross-sectional thickness T1 and greater than (e.g., at least 5%, such as at least 20%) the second nominal cross-sectional thickness T2. In one or more embodiments, the first nominal cross-sectional thickness T1 is the same as the second nominal cross-sectional thickness T2. In one or more embodiments, the first nominal cross-sectional thickness T1, the second nominal cross-sectional thickness T2, and the third nominal cross-sectional thickness T3 are the same.

[0038] like Figure 2AAs shown, the first layer 110 has a fourth nominal cross-sectional thickness T4, which is adjacent to each of the plurality of bases 140 of the second layer 120. The first layer 110 also has a fifth nominal cross-sectional thickness T5 located below each of the plurality of beaded portions 130. In one or more instances, the fifth nominal cross-sectional thickness T5 is the same as the sum of the first nominal cross-sectional thickness T1 and the fourth nominal cross-sectional thickness T4. The fifth nominal cross-sectional thickness T5 is greater than the fourth nominal cross-sectional thickness T4, such that the second layer 120 is configured to be self-nested with the first layer 110. In one or more instances, the fifth nominal cross-sectional thickness T5 is the same as the third nominal cross-sectional thickness T3.

[0039] Reference Figure 2B When one or more of the multiple bead-like portions 130 have a circular cross-section, the circular bead-like portion 130 may have a nominal width W1 and a nominal height H1. In one or more instances, the ratio of the nominal height H1 to the nominal width W1 may be less than 1. In other instances, the ratio of the nominal height H1 to the nominal width W1 is 1. In still other instances, such as Figure 2B As shown, each of the plurality of bead-like portions 130 is elongated, giving it a generally elliptical shape.

[0040] In one or more instances, such as Figure 3B As shown, each of the plurality of bead-like portions 130 includes a tapered end cap 138 that transitions into one of the plurality of base portions 140. The tapered end cap 138 has a flared geometry to transition from the cap-shaped or rounded bead-like portion 130 to a generally planar portion of the second layer 120. In one or more embodiments, the tapered end cap 138 is integrated with the second layer 120 such that they are a single integral unit. In one or more embodiments, the tapered end cap 138 is formed separately (e.g., by stamping) and then co-cured with the second layer 120 to achieve integration.

[0041] like Figure 2A and 2B As shown, the layered structure 105 defines a transition region 136 in which the second layer 120 transitions from one of a plurality of bases 140 to one of a plurality of bead-like portions 130. In one or more embodiments, a filler material 155 is disposed in the transition region 136 between the first layer 110 and the second layer 120. The filler material 155 defines a rounded corner region within the transition region 136. In one or more embodiments, the filler material 155 is co-cured with at least one of the first layer 110 and the second layer 120 of the layered structure 105.

[0042] Figure 4A portion of an exemplary embodiment of the second layer 120 is shown. In one or more instances, the second layer 120 includes at least one integral flange 128. The integral flange 128 is configured to align with the spar 175. In one or more instances, the integral flange 128 is parallel to the spar 175.

[0043] In one or more embodiments, the first layer 110 and the second layer 120 of the disclosed composite structure 100 may be co-cured to produce a layered structure 105 of the composite structure 100. Alternatively, the layered structure 105 of the disclosed composite structure 100 may include an adhesive (not shown) disposed between the first layer 110 and the second layer 120. The adhesive may be positioned along the base 140 of the second layer 120 on a first main surface 112 of the first layer 110. Figure 2B ) and the second main surface 122 of the second layer 120 ( Figure 2B )between.

[0044] like Figure 3A As shown, an aircraft wing 170 is disclosed. The aircraft wing 170 may be generally tapered in shape. In one or more embodiments, the aircraft wing 170 includes a lower skin panel 190 and an upper skin panel 180. At least one of the upper skin panel 180 and the lower skin panel 190 includes the disclosed composite structure 100, which comprises a first layer 110 and a second layer 120. The second layer 120 is connected to the first layer 110 to form a layered structure 105. In one or more embodiments, the second layer 120 includes a plurality of bases 140 adjacent to the first layer 110. The second layer 120 also includes a plurality of bead-like portions 130 projecting from the plurality of bases 140. In one or more embodiments, each of the plurality of bead-like portions 130 defines a channel 135 between the first layer 110 and the second layer 120. The plurality of bead-like portions 130 may include eight bead-like portions 130. In one or more embodiments, at least one system feature 300 is disposed in the plurality of channels 135. System feature 300 is one of wire 310, conduit 320 or any other system feature 300 provided herein.

[0045] In one or more instances, such as Figure 1As shown, both the upper skin panel 180 and the lower skin panel 190 have a layered structure 105 including a first layer 110 and a second layer 120. The second layer 120 is connected to the first layer 110 to form the layered structure 105. In one or more embodiments, the second layer 120 includes a plurality of bases 140 adjacent to the first layer 110. The second layer 120 also includes a plurality of beaded portions 130 projecting from the plurality of bases 140. In one or more embodiments, each of the plurality of beaded portions 130 defines a channel 135 between the first layer 110 and the second layer 120. The plurality of beaded portions 130 may include eight beaded portions 130. In one or more embodiments, at least one system feature 300 is disposed in the plurality of channels 135. The system feature 300 is one of a wire 310, a conduit 320, or any other system feature 300 provided herein.

[0046] In one or more embodiments, the aircraft wing 170 includes a fluid-tight volume 177 defined at least partially by an upper skin panel 180, a lower skin panel 190, and a spar 175. A plurality of channels 135 are fluidly isolated from the fluid-tight volume 177, such that no liquid contamination occurs within any system feature 300 disposed within one of the channels 135. In one or more embodiments, the aircraft wing 170 includes at least one rib 173 disposed between the upper skin panel 180 and the lower skin panel 190. The at least one rib 173, together with the upper skin panel 180, the lower skin panel 190, and the spar 175, defines the fluid-tight volume 177. In one or more embodiments, the aircraft wing 170 includes more than one rib 173 defining more than one fluid-tight volume 177. In one or more embodiments, at least one fluid-tight volume 177 is a fuel tank.

[0047] Figure 5A A flowchart of a method 200 for manufacturing a composite structure 100 is shown. Method 200 includes a deposition step 210: depositing a composite material onto a tool to form a second layer 120. The second layer 120 includes a plurality of bead-like portions 130 and a plurality of base portions 140. In one or more instances, the plurality of bead-like portions 130 define a plurality of channels 135.

[0048] In one or more instances, method 200 includes a distribution step 220: distributing a plurality of mandrels on a second layer 120 to define channels in a plurality of bead-like portions 130. In one or more instances, distributing the plurality of mandrels 220 includes distributing a plurality of soluble mandrels 220 times. In one or more instances, the plurality of soluble mandrels includes a ceramic material. The ceramic material is soluble in water. In one or more instances, the plurality of bead-like portions 130 define a plurality of channels 135.

[0049] In one or more instances, method 200 includes a deposition step 230: depositing a composite material onto a second layer 120 and a plurality of mandrels to form a first layer 110. The first layer 110 does not have beaded portions 130.

[0050] In one or more instances, method 200 includes a bonding step 240: bonding a first layer 110 to a second layer 120. Bonding 240 is achieved by simultaneously or sequentially curing 253 one or more of the first layer 110 and the second layer 120. Curing 253 may be performed in an autoclave. In one or more instances, bonding 240 includes curing 253 of the first layer 110. In one or more instances, bonding 240 includes curing 253 of the adhesive disposed between the first layer 110 and the second layer 120. In one or more instances, bonding 240 includes curing 253 of the second layer 120.

[0051] In one or more instances, a method 200 for manufacturing a composite structure 100 includes a joining step 250: connecting a first layer 110 to a second layer 120 to form a layered structure 105. The second layer 120 of the layered structure 105 includes a plurality of bases 140 adjacent to the first layer 110 and a plurality of bead-like portions 130 projecting from the plurality of bases 140. In one or more instances, each of the plurality of bead-like portions 130 defines a channel 135 between the first layer 110 and the second layer 120.

[0052] In one or more instances, the connection 250 includes co-curing 259 a first layer 110 and a second layer 120 to form a layered structure 105.

[0053] Figure 5B An exemplary embodiment of the connection 250 is shown. In one or more instances, the connection 250 includes curing 253 a first layer 110 and a second layer 120 to produce a cured first layer 110' and a cured second layer 120', respectively. The connection 250 also includes bonding 255 of the cured first layer 110' to the cured second layer 120' to form a layered structure 105.

[0054] Figure 5C Another exemplary embodiment of the connection 250 is shown. In one or more instances, the connection 250 includes curing one of the first layer 110 and the second layer 120 to produce a cured layer 106 and an uncured layer 108. The connection 250 also includes applying an adhesive 257 between the cured layer 106 and the uncured layer 108. The connection 250 further includes co-curing the adhesive 259 and the uncured layer 108 to form a layered structure 105.

[0055] Examples of the topics disclosed in this article can be found in, for example... Figure 7 The aircraft manufacturing and maintenance methods 1100 shown and such Figure 8The illustration is set against the background of aircraft 1102. During pre-production, illustrative method 1100 may include the specifications and design of aircraft 1102 (box 1104) and material procurement (box 1106). During production, the manufacturing of components and sub-assemblies of aircraft 1102 (box 1108) and system integration (box 1110) may be performed. Subsequently, aircraft 1102 may be certified and delivered (box 1112) for service (box 1114). During service, aircraft 1102 may be scheduled for routine maintenance and servicing (box 1116). Routine maintenance and servicing may include modification, reconfiguration, refurbishment, etc., of one or more systems of aircraft 1102.

[0056] Each process of illustrative method 1100 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 description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and main system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service provider, etc.

[0057] like Figure 8 As shown, an aircraft 1102 produced by illustrative method 1100 may include a fuselage 1118 having multiple advanced systems 1120 and an interior 1122. Examples of advanced systems 1120 include one or more of a propulsion system 1124, an electrical system 1126, a hydraulic system 1128, and an environmental system 1130. Any number of other systems may be included. Although an aviation example is shown, the principles disclosed herein can be applied to other industries, such as the automotive industry. Therefore, in addition to aircraft 1102, the principles disclosed herein can also be applied to other vehicles of transportation, such as land vehicles, marine vehicles, space vehicles, etc.

[0058] The apparatus and methods shown or described herein may be used during any one or more stages of manufacturing and maintenance method 1100. For example, components and subassemblies corresponding to the manufacturing of parts and subassemblies (box 1108) may be assembled or manufactured in a manner similar to that of components and subassemblies produced during the commissioning of aircraft 1102 (box 1114). Furthermore, one or more instances of the apparatus, method, or combination thereof may be utilized during the production stages (boxes 1108 and 1110), for example, by accelerating the assembly of aircraft 1102 or reducing its cost. Similarly, one or more instances of the apparatus or method, or combinations thereof, may be utilized, for example, but not limited to, during the service of aircraft 1102 (box 1114) and / or during maintenance and servicing (box 1116).

[0059] Further illustrative and non-exclusive examples of this disclosure are described in the following paragraphs:

[0060] In an example according to this disclosure, the composite structure (100) includes:

[0061] First layer (110); and

[0062] A second layer (120) is connected to the first layer (110) to form a layered structure (105), the second layer (120) comprising:

[0063] Multiple bases (140), adjacent to the first layer (110); and

[0064] Multiple bead-like portions (130) protrude from multiple base portions (140), each of the multiple bead-like portions (130) defining a channel (135) between the first layer (110) and the second layer (120).

[0065] Optionally, in the composite structure (100) of the aforementioned paragraph, the first layer (110) does not have a beaded portion (130).

[0066] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, both the first layer (110) and the second layer (120) contain composite materials.

[0067] Optionally, in the composite structure (100) of one of the preceding paragraphs, the composite material includes a reinforcing material encapsulated in a polymer matrix material.

[0068] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, the plurality of bases (140) and the plurality of beaded portions (130) of the second layer (120) comprise a single integral.

[0069] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, an adhesive disposed between the first layer (110) and the second layer (120) is also included.

[0070] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, the adhesive is disposed along the base (140) of the second layer (120) between the first main surface (112) of the first layer (110) and the second main surface (122) of the second layer (120).

[0071] Alternatively, in the composite structure (100) of one of the aforementioned paragraphs, the first layer (110) defines an access hole (150) that provides an entrance to a passage (135) between the first layer (110) and the second layer (110).

[0072] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, each of the plurality of bead-like portions (130) includes opposing sidewall portions (132) and a cover portion (134) located between the opposing sidewall portions (132).

[0073] Alternatively, in the compound structure (100) of one of the aforementioned paragraphs, wherein:

[0074] Multiple bases (140) have a first nominal cross-sectional thickness (T1),

[0075] The opposing sidewall portion (132) has a second nominal cross-sectional thickness (T2).

[0076] The cover (134) has a third nominal cross-sectional thickness (T3), and

[0077] The third nominal section thickness (T3) is greater than the first nominal section thickness (T1) and greater than the second nominal section thickness (T2).

[0078] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, the first nominal section thickness (T1) is the same as the second nominal section thickness (T2).

[0079] Alternatively, in the compound structure (100) of one of the aforementioned paragraphs, wherein:

[0080] Multiple bases (140) have a first nominal cross-sectional thickness (T1),

[0081] The opposing sidewall portion (132) has a second nominal cross-sectional thickness (T2).

[0082] The cover (134) has a third nominal cross-sectional thickness (T3), and

[0083] The first nominal section thickness (T1), the second nominal section thickness (T2), and the third nominal section thickness (T3) are the same.

[0084] Alternatively, in the compound structure (100) of one of the aforementioned paragraphs, wherein:

[0085] Multiple bases (140) have a first nominal cross-sectional thickness (T1),

[0086] The first layer (110) has a fourth nominal cross-sectional thickness (T4) located at each of the plurality of bases (140),

[0087] The first layer (110) has a fifth nominal cross-sectional thickness (T5) located at each of the plurality of beaded portions (130), and

[0088] The fifth nominal section thickness (T5) is the same as the sum of the first nominal section thickness (T1) and the fourth nominal section thickness (T4).

[0089] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, the layered structure (105) defines a transition region (136) in which the second layer (120) transitions from the base (140) of the plurality of bases (140) to the bead (130) of the plurality of bead portions (130), and wherein the filling material (155) is disposed in the transition region (136) between the first layer (110) and the second layer (120).

[0090] Alternatively, in the composite structure (100) of one of the aforementioned paragraphs, the layered structure (105) defines the access hole (150).

[0091] Optionally, in one of the aforementioned paragraphs of the composite structure (100), there is a manhole cover (151) that seals the manhole (150).

[0092] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, the second layer (120) includes at least one integral flange (128).

[0093] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, each of the plurality of beaded portions (130) is cap-shaped.

[0094] Alternatively, in the compound structure (100) of one of the aforementioned paragraphs, wherein:

[0095] Each of the plurality of bead-like portions (130) has a nominal width (W1).

[0096] Each of the plurality of bead-like portions (130) has a nominal height (H1), and

[0097] The ratio of nominal height (H1) to nominal width (W1) is less than 1.

[0098] Alternatively, in the composite structure (100) of one of the aforementioned paragraphs, each of the plurality of bead-like portions (130) is elongated.

[0099] Optionally, in the composite structure (100) of one of the aforementioned paragraphs, each of the plurality of bead portions (130) includes a tapered end cap (138) that transitions into the base (140) of the plurality of base portions (140).

[0100] In another example according to this disclosure, an aircraft wing (170) includes:

[0101] Upper skin panel (180); and

[0102] The lower skin panel (190), wherein at least one of the upper skin panel (180) and the lower skin panel (190) includes:

[0103] First layer (110); and

[0104] A second layer (120) is connected to the first layer (110) to form a layered structure (105), the second layer (120) comprising:

[0105] Multiple bases (140), adjacent to the first layer (110); and

[0106] Multiple bead-like portions (130) protrude from multiple base portions (140), each of the multiple bead-like portions (130) defining an associated channel (135) among multiple channels (135) between the first layer (110) and the second layer (120).

[0107] Optionally, the aircraft wing (170) described in the preceding paragraph includes at least one spar (175) disposed between the upper skin panel (180) and the lower skin panel (190).

[0108] Optionally, the aircraft wing (170) in one of the preceding paragraphs includes a fluid-tight volume (177) defined at least in part by:

[0109] Upper skin panel (180),

[0110] Lower skin panel (190), and

[0111] Wing spars (175).

[0112] Alternatively, in one of the aforementioned paragraphs, in the aircraft wing (170), multiple channels (135) are fluidly isolated from the fluid-sealed volume (177).

[0113] Optionally, in one of the aforementioned paragraphs, the system feature (300) is disposed in a plurality of channels (135) in the aircraft wing (170).

[0114] Optionally, in one of the aforementioned paragraphs, the system feature (300) in the aircraft wing (170) is at least one of wire (310) and conduit (320).

[0115] Optionally, in one of the aforementioned paragraphs, the aircraft wing (170) includes at least one rib (173) disposed between the upper skin panel (180) and the lower skin panel (190).

[0116] In another embodiment of this disclosure, a method (200) for manufacturing a composite structure (100) is disclosed, the method (200) comprising:

[0117] In the deposition step (210), the composite material is deposited on the tool to form a second layer (120), the second layer (120) having a plurality of bases (140) and a plurality of bead-like portions (130);

[0118] In the distribution step (220), multiple mandrels are distributed on the second layer (120) to define channels in multiple bead-like portions (130);

[0119] In the deposition step (230), the composite material is deposited on the second layer (120) and multiple mandrels to form the first layer (110); and

[0120] In the bonding step (240), the first layer (110) is bonded to the second layer (120).

[0121] Optionally, in the method (200) of the preceding paragraph, distributing multiple mandrels in the distribution step (220) includes distributing (220) multiple soluble mandrels.

[0122] Alternatively, in one of the methods (200) in the preceding paragraphs, the plurality of soluble mandrels include ceramic materials.

[0123] Alternatively, in one of the methods (200) in the preceding paragraphs, the bonding step (240) includes curing the first layer (110).

[0124] Optionally, in one of the methods (200) in the preceding paragraphs, the bonding step (240) includes curing the adhesive disposed between the first layer (110) and the second layer (120).

[0125] Optionally, in one of the methods (200) in the preceding paragraphs, the bonding step (240) includes curing the second layer (120).

[0126] In another embodiment of this disclosure, a method (200) for manufacturing a composite structure (100) is disclosed, the method (200) comprising:

[0127] In the connection step (250), the first layer (110) is connected to the second layer (120) to form a layered structure (105), the second layer (120) comprising:

[0128] Multiple bases (140), adjacent to the first layer (110); and

[0129] Multiple bead-like portions (130) protrude from multiple base portions (140), each of the multiple bead-like portions (130) defining a channel (135) between the first layer (110) and the second layer (120).

[0130] Optionally, in the method (200) of the preceding paragraph, the bonding step (250) includes co-curing the first layer (110) and the second layer (120).

[0131] Optionally, in one of the methods (200) of the preceding paragraphs, the connection step (250) includes:

[0132] The first layer (110) and the second layer (120) are cured respectively to produce a cured first layer (110') and a cured second layer (120'); and

[0133] The cured first layer (110′) is bonded to the cured second layer (120′).

[0134] Optionally, in one of the methods (200) of the preceding paragraphs, the connection step (250) includes:

[0135] One of the first layer (110) and the second layer (120) is cured to produce a cured layer (106) and an uncured layer (108);

[0136] An adhesive is applied between the cured layer (106) and the uncured layer (108); and

[0137] Co-cured adhesive and uncured layer (108).

[0138] The various examples of the apparatuses and methods disclosed herein include a wide range of components, features, and functions. It should be understood that the various examples of the apparatuses and methods disclosed herein may include any combination of any components, features, and functions of any other example of the apparatuses and methods disclosed herein.

[0139] Although various examples of the disclosed beaded composite structures and methods for manufacturing beaded composite structures have been shown and described, modifications will occur to those skilled in the art upon reading the specification. This application includes such modifications and is limited only by the scope of the claims.

[0140] Therefore, it should be understood that the subject matter disclosed herein is not limited to the specific examples shown, and modifications and other examples are intended to be included within the scope of the appended claims. Furthermore, although the foregoing description and associated drawings illustrate examples of the subject matter disclosed herein, it should be understood that different combinations of elements and / or functions may be provided by alternative embodiments without departing from the scope of the appended claims, within the context of certain illustrative combinations of elements and / or functions. Therefore, the reference numerals in parentheses in the appended claims are for illustrative purposes only and are not intended to limit the scope of the claimed subject matter to the specific examples provided herein.

Claims

1. A composite structure (100), comprising: First layer (110); as well as A second layer (120) is connected to the first layer (110) to form a layered structure (105), the second layer (120) comprising: Multiple bases (140) adjacent to the first layer (110); and A plurality of bead-like portions (130) protrude from the plurality of base portions (140), each of the plurality of bead-like portions (130) defining a channel (135) between the first layer (110) and the second layer (120). The layered structure (105) defines one or more access holes (150) extending through the first layer (110) and / or the second layer (120).

2. The composite structure (100) according to claim 1, wherein, The first layer (110) does not have the beaded portion (130).

3. The composite structure (100) according to claim 1 or 2, wherein, When the first layer (110) defines at least one of the one or more access holes (150), the at least one access hole provides an entrance to the channel (135) between the first layer (110) and the second layer (120).

4. The composite structure (100) according to claim 1 or 2, wherein, Each of the plurality of bead-shaped portions (130) includes opposing sidewall portions (132) and a cover portion (134) located between the opposing sidewall portions (132).

5. The composite structure (100) according to claim 4, wherein: The plurality of bases (140) have a first nominal cross-sectional thickness (T1). The opposing sidewall portion (132) has a second nominal cross-sectional thickness (T2). The cover (134) has a third nominal cross-sectional thickness (T3), and The third nominal section thickness (T3) is greater than the first nominal section thickness (T1) and greater than the second nominal section thickness (T2).

6. The composite structure (100) according to claim 5, wherein, The first nominal section thickness (T1) is the same as the second nominal section thickness (T2).

7. The composite structure (100) according to claim 4, wherein: The plurality of bases (140) have a first nominal cross-sectional thickness (T1). The opposing sidewall portion (132) has a second nominal cross-sectional thickness (T2). The cover (134) has a third nominal cross-sectional thickness (T3), and The first nominal cross-sectional thickness (T1), the second nominal cross-sectional thickness (T2), and the third nominal cross-sectional thickness (T3) are the same.

8. The composite structure (100) according to claim 4, wherein: The plurality of bases (140) have a first nominal cross-sectional thickness (T1). The first layer (110) has a fourth nominal cross-sectional thickness (T4) located at each of the plurality of bases (140). The first layer (110) has a fifth nominal cross-sectional thickness (T5) located at each of the plurality of bead portions (130), and The fifth nominal section thickness (T5) is the same as the sum of the first nominal section thickness (T1) and the fourth nominal section thickness (T4).

9. The composite structure (100) according to any one of claims 1, 2 and 5 to 8, wherein, The layered structure (105) defines a transition region (136) in which the second layer (120) transitions from one of the bases (140) to one of the bead portions (130) in the plurality of bead portions (130), and wherein a filling material (155) is disposed in the transition region (136) between the first layer (110) and the second layer (120).

10. The composite structure (100) according to any one of claims 1, 2 and 5 to 8, wherein: Each of the plurality of bead-shaped portions (130) has a nominal width (W1). Each of the plurality of bead-like portions (130) has a nominal height (H1), and The ratio of the nominal height (H1) to the nominal width (W1) is less than 1.

11. A method (200) for manufacturing a composite structure (100), the method (200) comprising: In the deposition step (210), the composite material is deposited on the tool to form a second layer (120) having a plurality of bead-like portions (130) and a plurality of base portions (140). In the distribution step (220), a plurality of mandrels are distributed on the second layer (120) to define channels (135) in the plurality of bead-like portions (130). In the deposition step (230), the composite material is deposited on the second layer (120) and the plurality of mandrels to form the first layer (110). as well as In the bonding step (240), the first layer (110) is bonded to the second layer (120) to form a layered structure (105). The layered structure (105) defines one or more access holes (150) extending through the first layer (110) and / or the second layer (120).

12. The method (200) according to claim 11, wherein, The distribution of the plurality of mandrels in the distribution step (220) includes the distribution of a plurality of soluble mandrels.

13. The method (200) according to claim 11 or 12, wherein, The bonding step (240) includes curing the first layer (110).

14. The method (200) according to claim 11 or 12, wherein, The bonding step (240) includes curing the adhesive disposed between the first layer (110) and the second layer (120).

15. The method (200) according to claim 11 or 12, wherein, The bonding step (240) includes curing the second layer (120).

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