Bead-shaped composite material structure, and method for manufacturing a bead-shaped composite material structure
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Patents
- Current Assignee / Owner
- THE BOEING CO
- Filing Date
- 2022-01-18
- Publication Date
- 2026-08-04
Smart Images
Figure 0007900155000001 
Figure 0007900155000002 
Figure 0007900155000003
Abstract
Description
Technical Field
[0001] This application relates to composite structures, and more particularly, to composite structures and methods of manufacturing composite structures.
Background Art
[0002] In a typical structural design for components of an aircraft wing, it is necessary to manufacture blade stringers and vent stringers separately before joining or co-curing (integrated curing). The process of manufacturing separately is costly and time-consuming. In addition, a typical structural design for an aircraft wing requires the use of numerous components that add weight to the entire structure. Furthermore, the space between the upper and lower parts of an aircraft wing is typically narrow, making it difficult to access this space during initial assembly and subsequent maintenance. Once the aircraft wing is assembled, access to this space is restricted.
[0003] Therefore, those skilled in the art have continued their research and development efforts in the field of composite structure manufacturing.
Summary of the Invention
[0004] A bead-shaped composite structure is disclosed.
[0005] In one or more examples, 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 base portions that abut against the first layer and a plurality of bead-shaped portions that protrude from the plurality of base portions. Each bead-shaped portion of the plurality of bead-shaped portions defines a channel between the first layer and the second layer.
[0006] Also disclosed is a method of manufacturing a composite structure.
[0007] In one or more embodiments, the disclosed method for manufacturing a composite structure uses a tool to form a second layer On top ofThe method includes depositing a composite material. The second layer has a plurality of bead-like portions and a plurality of base portions. The method further includes dispersing a plurality of mandrels on the second layer to define channels in the plurality of bead-like portions. The method further includes depositing a 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 embodiments of the disclosed bead-like composite structure and methods for manufacturing the bead-like composite structure will become apparent from the following detailed description, the accompanying drawings, and the accompanying claims. [Brief explanation of the drawing]
[0009] [Figure 1] This is a perspective view of a composite material structure. [Figure 2A] This is a perspective view of the bead-shaped portion of the composite material structure. [Figure 2B] Figure 1 is a perspective view of the bead-shaped portion of the composite material structure. [Figure 3A] This is a top view of an airplane wing. [Figure 3B] Figure 3A is a perspective view of the bead-shaped portion of the wing. [Figure 4] Figure 1 is a perspective view of a part of the composite material structure. [Figure 5A] Figure 1 is a flowchart showing the method for manufacturing the composite material structure. [Figure 5B] This is a flowchart of part of the method shown in Figure 5A. [Figure 5C] This is a flowchart of part of the method shown in Figure 5A. [Figure 6] This is a perspective view of a composite material structure. [Figure 7] This is a block diagram of the manufacturing and maintenance methods for aircraft. [Figure 8] This is a schematic diagram of an aircraft. [Modes for carrying out the invention]
[0010] In the following description, numerous specific details are included to provide a complete understanding of the disclosed concepts, although the concepts may be practiced without some or all of these details. In other instances, details of known apparatus and / or processes are omitted to avoid unnecessarily complicating the disclosure. Some concepts will be described in conjunction with specific embodiments, but these embodiments are not intended to be limiting.
[0011] Unless otherwise indicated, terms such as “first,” “second,” etc., are used solely as symbols in this specification and are not intended to impose any sequential, positional, or hierarchical requirements on the items they refer to. Furthermore, a reference to, for example, an item “second,” does not require or exclude the existence of, for example, an item “first,” i.e., a lesser numbered item, and / or, for example, an item “third,” i.e., a more larger numbered item.
[0012] Any reference in this specification to "one or more examples" means that one or more features, structures, or characteristics described in relation to that example are included in at least one embodiment. The phrase "one or more examples" found elsewhere in this specification may or may not refer to the same examples.
[0013] In this specification, a system, apparatus, structure, article, element, component, or hardware "configured to" perform a particular function is, in fact, capable of performing that particular function without any modification, rather than merely having the potential to perform that particular function after further modification. In other words, a system, apparatus, structure, article, element, component, or hardware "configured to" perform a particular function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing that particular function. In this specification, the expression "configured to" refers to an existing feature of the system, apparatus, structure, article, element, component, or hardware that enables the system, apparatus, structure, article, element, component, or hardware to perform a particular function without further modification. In this disclosure, any system, apparatus, structure, article, element, component, or hardware described as “configured to” perform a particular function may, additionally or alternatively, be described as “adapted to” and / or “operable to” perform that function.
[0014] Exemplary and non-exclusive examples of the subject matter of the inventions disclosed herein are provided below.
[0015] Figure 1 shows a perspective view of a composite structure 100 including a first layer 110 and a second layer 120. The first layer 110 is connected to the second layer 120 to form a layered structure 105. Although the composite structure 100 is shown in Figure 1 as an outer skin panel for an aircraft wing, those skilled in the art will see that the disclosed composite structure 100 can be used in a variety of applications, including a variety of applications outside the aerospace industry.
[0016] In one or more examples, the second layer 120 of the composite structure 100 includes a plurality of base portions 140 and a plurality of bead-like portions 130. The plurality of base portions 140 can abut the first layer 110 within the layered structure 105 of the composite structure 100. The plurality of bead-like portions 130 can protrude from the plurality of base portions 140. Thus, each bead-like portion 130 of the plurality of bead-like portions 130 defines an associated channel 135 between the first layer 110 and the second layer 120, whereby the composite structure 100 includes a plurality of channels 135.
[0017] In one or more examples, at least one system feature (equipment of the system) 300 can be disposed within at least one channel 135 of the plurality of channels 135. The system feature 300 can be, for example, wiring 310, conduit 320, cables, tubes, optical fibers, etc. Various other system features 300 can be accommodated within the plurality of channels 135 without departing from the scope of the present disclosure.
[0018] In one or more examples, the second layer 120 of the composite structure 100 can be formed from, or include, a composite material. The composite material of the second layer 120 can include a reinforcing material encapsulated in a polymer matrix material. As a specific non-limiting example, the reinforcing material can be, or include, carbon fibers, glass fibers, etc., and the polymer matrix material can be, or include, a thermosetting (e.g., epoxy) resin. The use of various thermosetting resins such as polyaryletherketone is also contemplated.
[0019] In one or more examples, the layered structure 105 of the composite material structure 100 defines one or more access openings 150. In one variant, the access opening 150 penetrates both the first layer 110 and the second layer 120. In other variants, the access opening 150 penetrates only the first layer 110 of the layered structure 105. In yet another variant, the access opening 150 penetrates only the second layer 120 of the layered structure 105. Thus, the access opening 150 may be located in a bead-shaped portion 130 of the plurality of bead-shaped portions 130 (FIG. 6), may be located on a base portion 140 of the plurality of base portions 140, or the composite material structure 100 may include more than one access opening 150, where at least one access opening 150 is located in a bead-shaped portion 130 and at least one access opening 150 is located on a base portion 140.
[0020] At least one access opening 150 illustrated in FIG. 6 allows access to a bead-shaped portion 130 of the plurality of bead-shaped portions 130 for maintenance. One or more system features 300 may be located within a bead-shaped portion 130 of the plurality of bead-shaped portions 130. The access opening 150 allows one or more system features 300 to be taken out of the bead-shaped portion 130.
[0021] As illustrated in FIG. 1, in one or more examples, the composite material structure 100 may further include an access panel 151 (FIG. 1) that seals at least one access opening 150. The access panel 151 may be liquid-tight so as to prevent liquid from flowing through the associated access opening 150. The access panel 151 (fuel dam) is configured to be easily accessible to the wing 170 of an aircraft for external inspection and repair, and thus the need to enter a narrow space is reduced.
[0022] In one or more examples, the first layer 110 of the composite material structure 100 is not provided with bead-shaped portions 130. Alternatively, although not shown in the figures, the first layer 110 may include a plurality of bead-shaped portions 130 and a plurality of base portions 140, similar to the second layer 120.
[0023] In one or more examples, the first layer 110 of the composite structure 100 may be formed from or include a composite material. The composite material of the first layer 110 may include a reinforcing material encased in a polymer matrix material. In certain non-limiting examples, the reinforcing material may be (or may include) carbon fibers, glass fibers, etc., and the polymer matrix material may be (or may include) a thermosetting (e.g., epoxy) resin. The use of various thermosetting resins such as polyaryletherketones is also being considered.
[0024] As best illustrated in Figures 2A and 2B, in one or more examples, the first layer 110 may define an access opening 150 that provides access to a channel 135 (Figure 1) between the first layer 110 and the second layer 120. Those skilled in the art will see that the composite structure 100 may include more than one access opening 150 that provides access to multiple channels 135 (Figure 1).
[0025] Figures 2A and 2B show two examples of bead-shaped parts 130 from among the multiple bead-shaped parts 130. Specifically, Figure 2A shows a bead-shaped part 130 with a roughly hat-shaped cross-section, and Figure 2B shows a bead-shaped part 130 with a roughly circular cross-section.
[0026] As shown in Figure 2A, each of the multiple bead-shaped portions 130 may include opposing sidewall portions 132 and a cap portion 134 extending between the sidewall portions 132. In one or more examples, the multiple 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 cap portion 134 has a third nominal cross-sectional thickness T3. In one or more examples, the third nominal cross-sectional thickness T3 is greater than the first nominal cross-sectional thickness T1 (e.g., at least 5 percent greater, e.g., at least 20 percent greater) and greater than the second nominal cross-sectional thickness T2 (e.g., at least 5 percent greater, e.g., at least 20 percent greater). In one or more examples, the first nominal cross-sectional thickness T1 is the same as the second nominal cross-sectional thickness T2. In one or more examples, 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.
[0027] As shown in Figure 2A, the first layer 110 has a fourth nominal cross-sectional thickness T4 near each of the multiple base portions 140 of the second layer 120. The first layer 110 further has a fifth nominal cross-sectional thickness T5 below each of the multiple bead-like portions 130. In one or more examples, the fifth nominal cross-sectional thickness T5 is equal to 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, so that the second layer 120 is configured to self-nest within the first layer 110. In one or more examples, the fifth nominal cross-sectional thickness T5 is the same as the third nominal cross-sectional thickness T3.
[0028] Referring to Figure 2B, when the cross-section of one or more of the multiple bead-shaped parts 130 is circular, the circular bead-shaped parts 130 may have a nominal width W1 and a nominal height H1. In one or more examples, the ratio of the nominal height H1 to the nominal width W1 may be less than 1. In other examples, the ratio of the nominal height H1 to the nominal width W1 is 1. In yet another example, as shown in Figure 2B, each of the multiple bead-shaped parts 130 is elongated so as to form an approximately elliptical shape.
[0029] In one or more examples, as shown in Figure 3B, each of the multiple bead-shaped portions 130 includes a tapered end cap portion 138 that transitions to one of the base portions 140. The tapered end cap portion 138 has an outwardly projecting shape to transition from a hat-shaped or circular bead-shaped portion 130 to a substantially planar portion of the second layer 120. In one or more examples, the tapered end cap portion 138 is integrated with the second layer 120 to form a single, integrated body. In one or more examples, the tapered end cap portion 138 is formed separately, for example by punching, and then co-cured together with the second layer 120 for integration.
[0030] As shown in Figures 2A and 2B, the layered structure 105 defines a transition region 136 in which the second layer 120 transitions from one of the base portions 140 to one of the bead portions 130. In one or more examples, a filler 155 is placed in the transition region 136 between the first layer 110 and the second layer 120. The filler 155 defines a fillet region within the transition region 136. In one or more examples, the filler 155 is cocued with at least one of the first layer 110 or the second layer 120 of the layered structure 105.
[0031] Figure 4 shows a portion of an exemplary embodiment of the second layer 120. In one or more embodiments, the second layer 120 includes at least one joint flange 128. The joint flange 128 is configured to align with the spar 175. In one or more examples, the joint flange 128 is parallel to the spar 175.
[0032] In one or more examples, the first layer 110 and the second layer 120 of the disclosed composite structure 100 can be cocured, thereby obtaining 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) placed between the first layer 110 and the second layer 120. The adhesive may be placed between the first main surface 112 of the first layer 110 (Figure 2B) and the second main surface 122 of the second layer 120 (Figure 2B) along the base portion 140 of the second layer 120.
[0033] As shown in Figure 3A, an aircraft wing 170 is disclosed. The aircraft wing 170 may have a substantially tapered shape. In one or more examples, 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 a disclosed composite structure 100 consisting of 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 examples, the second layer 120 includes a plurality of base portions 140 that abut the first layer 110. The second layer 120 further includes a plurality of bead-like portions 130 that protrude from the plurality of base portions 140. In one or more examples, each of the bead-shaped portions 130 defines a channel 135 between the first layer 110 and the second layer 120. The bead-shaped portions 130 may include eight bead-shaped portions 130. In one or more examples, at least one system feature 300 is located within the channel 135. The system feature 300 is one of the wiring 310, the conduit 320, or any other system feature 300 provided within these.
[0034] In one or more examples, as shown in Figure 1, both the upper outer panel 180 and the lower outer 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 examples, the second layer 120 includes a plurality of base portions 140 that abut the first layer 110. The second layer 120 further includes a plurality of bead-like portions 130 that protrude from the plurality of base portions 140. In one or more examples, 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 examples, at least one system feature 300 is located within the plurality of channels 135. The system feature 300 is one of the wiring 310, the conduit 320, or any other system feature 300 provided within them.
[0035] In one or more examples, the aircraft wing 170 includes a liquid-tight volume chamber 177 defined at least partially by an upper skin panel 180, a lower skin panel 190, and a spar 175. Multiple channels 135 are fluidly isolated from the liquid-tight volume chamber 177, so that liquid does not contaminate any system feature 300 located within one of the channels 135. In one or more examples, the aircraft wing 170 includes at least one rib 173 located 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 liquid-tight volume chamber 177. In one or more examples, the aircraft wing 170 includes one or more ribs 173 defining one or more liquid-tight volume chambers 177. In one or more examples, at least one liquid-tight volume chamber 177 is a fuel tank.
[0036] Figure 5A shows a flowchart of method 200 for manufacturing the composite structure 100. Method 200 involves using tools to form the second layer 120. On top ofThe process includes depositing a composite material (210). The second layer 120 has a plurality of bead-like portions 130 and a plurality of base portions 140. In one or more examples, the plurality of bead-like portions 130 define a plurality of channels 135.
[0037] In one or more examples, method 200 further includes dispersing a plurality of mandrels on a second layer 120 (220) to define channels in a plurality of bead-like portions 130. In one or more examples, dispersing a plurality of mandrels (220) includes dispersing a plurality of soluble mandrels (220). In one or more examples, the plurality of soluble mandrels comprises a ceramic material. The ceramic material is soluble in water. In one or more examples, the plurality of bead-like portions 130 define a plurality of channels 135.
[0038] In one or more examples, method 200 includes depositing a composite material on a second layer 120 and a plurality of mandrels to form a first layer 110 (230). The first layer 110 is not provided with bead-like portions 130.
[0039] In one or more examples, method 200 includes bonding the first layer 110 to the second layer 120 (240). The bonding (240) is achieved by curing one or more of the first layer 110 and the second layer 120 simultaneously or sequentially (253). The curing (253) may be carried out in an autoclave. In one or more embodiments, the bonding (240) includes curing the first layer 110 (253). In one or more examples, the bonding (240) includes curing an adhesive placed between the first layer 110 and the second layer 120 (253). In one or more embodiments, the bonding (240) includes curing the second layer 120 (253).
[0040] In one or more examples, a method 200 for manufacturing a composite structure 100 includes connecting a first layer 110 to a second layer 120 (250) to form a layered structure 105. The second layer of the layered structure 105 has a plurality of base portions 140 that abut against the first layer 110 and a plurality of bead-like portions 130 that protrude from the plurality of base portions 140. In one or more examples, each bead-like portion 130 of the plurality of bead-like portions 130 defines a channel 135 between the first layer 110 and the second layer 120.
[0041] In one or more examples, the connection (250) includes coquering (259) the first layer 110 and the second layer 120 to form a layered structure 105.
[0042] Figure 5B shows an exemplary embodiment of the joining (250) described above. In one or more examples, the joining (250) includes curing the first layer 110 and the second layer 120 separately (253) to obtain a cured first layer (110') and a cured second layer (120'). The joining (250) further includes joining (255) the cured first layer 110' to the cured second layer 120' in order to form a layered structure 105.
[0043] Figure 5C shows another exemplary embodiment of the connection (250) described above. In one or more examples, the connection (250) includes curing one of the first layer (110) and the second layer (120) to obtain a cured layer (106) and an uncured layer (108). The connection (250) further includes applying an adhesive (257) between the cured layer 106 and the uncured layer 108. The connection (250) further includes co-curing (259) the adhesive and the uncured layer 108 to form a layered structure 105.
[0044] Examples of the subject matter of the invention disclosed herein can be described in reference to the aircraft manufacturing and maintenance method 1100 shown in Figure 7 and the aircraft 1102 shown in Figure 8. In the pre-manufacturing stage, the exemplary method 1100 may include the specification and design of the aircraft 1102 (block 1104) and the procurement of materials (block 1106). In the manufacturing stage, the manufacturing of components and subassemblies of the aircraft 1102 (block 1108) and system integration (block 1110) may be carried out. Subsequently, the aircraft 1102 may be put into operation (block 1114) after approval and delivery (block 1112). During operation, the aircraft 1102 may be scheduled for periodic maintenance and upkeep (block 1116). Periodic maintenance and upkeep may include the modification, reconfiguration, or refurbishment of one or more systems of the aircraft 1102.
[0045] Each process of the exemplary 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 specification, the system integrator may include, but not limited to, any number of aircraft manufacturers and subcontractors of key systems; the third party may include, but not limited to, any number of vendors, subcontractors, and suppliers; and the operator may be an airline, leasing company, military organization, service organization, etc.
[0046] As shown in Figure 8, an aircraft 1102 manufactured by the exemplary method 1100 may include a fuselage 1118 having several high-level systems 1120 and interior 1122. Examples of high-level systems 1120 include one or more of the propulsion system 1124, electrical system 1126, hydraulic system 1128, and environmental system 1130. Any number of other systems may be included. Although an embodiment in the aerospace industry is shown here, the principles disclosed herein can also be applied to other industries such as the automotive industry. Correspondingly, the principles disclosed herein can be applied to other vehicles (e.g., land vehicles, marine vehicles, space vehicles, etc.) in addition to aircraft 1102.
[0047] The apparatus and methods shown or described herein can be used at any one or more stages of the manufacturing and maintenance method 1100. For example, components or subassemblies corresponding to the manufacture of components and subassemblies (block 1108) may be manufactured or produced in a similar manner to components or subassemblies manufactured during the operational period of aircraft 1102 (block 1114). Furthermore, one or more embodiments of the apparatus, methods, or combinations thereof may be used in the manufacturing stages (blocks 1108 and 1110) by, for example, substantially streamlining or reducing the cost of assembling aircraft 1102. Similarly, one or more examples of the implementation of the apparatus or methods, or combinations thereof, may be used, but are not limited to, during the operational period (block 1114) and / or during maintenance and servicing (block 1116) of aircraft 1102.
[0048] Exemplary and non-exclusive examples relating to this disclosure are described in the following paragraphs.
[0049] In one example relating to this disclosure, the composite material structure (100) is The first layer (110), A second layer (120) is connected to the first layer (110) to form a layered structure (105), Includes, The second layer (120) is, Multiple base portions (140) that abut the first layer (110), The present invention includes a plurality of bead-shaped portions (130) protruding from a plurality of base portions (140), wherein each bead-shaped portion (130) defines a channel (135) between a first layer (110) and a second layer (120).
[0050] Optionally, in the composite material structure (100) described in the previous paragraph, the first layer (110) is not provided with bead-shaped portions (130).
[0051] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, both the first layer (120) and the second layer (120) include the composite material.
[0052] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, the composite material includes a reinforcing material encased in a polymer matrix material.
[0053] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, the multiple base portions (140) and multiple bead-like portions (130) of the second layer (120) include a single integrated body.
[0054] Optionally, the composite structure (100) described in one of the preceding paragraphs further includes an adhesive placed between the first layer (110) and the second layer (120).
[0055] Optionally, in the composite structure (100) described in one of the preceding paragraphs, the adhesive is placed between the first main surface (112) of the first layer (120) and the second main surface (122) of the second layer (120) along the base portion (140) of the second layer (120).
[0056] Optionally, in the composite structure (100) described in one of the preceding paragraphs, the first layer (110) defines an access opening (150) that provides access to a channel (135) between the first layer (110) and the second layer (120).
[0057] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, each of the plurality of bead-shaped parts (130) includes opposing side wall parts (132) and a cap part (134) between the opposing side wall parts (132).
[0058] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, Multiple base portions (140) have a first nominal cross-sectional thickness (T1), The opposing side walls (132) have a second nominal cross-sectional thickness (T2), The cap portion (134) has a third nominal cross-sectional thickness (T3), The third nominal cross-sectional thickness (T3) is greater than the first nominal cross-sectional thickness (T1) and greater than the second nominal cross-sectional thickness (T2).
[0059] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, the first nominal cross-sectional thickness (T1) is the same as the second nominal cross-sectional thickness (T2).
[0060] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, Multiple base portions (140) have a first nominal cross-sectional thickness (T1), The opposing side walls (132) have a second nominal cross-sectional thickness (T2), The cap portion (134) has a third nominal cross-sectional thickness (T3), 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.
[0061] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, Multiple base portions (140) have a first nominal cross-sectional thickness (T1), The first layer (110) has a fourth nominal cross-sectional thickness (T4) in each of the multiple base portions (140), The first layer (110) has a fifth nominal cross-sectional thickness (T5) in each of the multiple bead-shaped portions (130). The fifth nominal cross-sectional thickness (T5) is equal to the sum of the first nominal cross-sectional thickness (T1) and the fourth nominal cross-sectional thickness (T4).
[0062] Optionally, in the composite structure (100) described in one of the preceding paragraphs, the layered structure (105) defines a transition region (136) in which the second layer (120) transitions from one of the base portions (140) to one of the bead-shaped portions (130), and the filler (155) is placed within the transition region (136) between the first layer (110) and the second layer (120).
[0063] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, the layered structure (105) defines the access opening (150).
[0064] Optionally, the composite structure (100) described in one of the preceding paragraphs includes an access panel (151) that seals the access opening (150).
[0065] Optionally, in the composite structure (100) described in one of the preceding paragraphs, the second layer (120) includes at least one joint flange (128).
[0066] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, each of the multiple bead-shaped parts (130) is hat-shaped.
[0067] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, Each of the multiple bead-shaped parts (130) has a nominal width (W1), Each of the multiple bead-shaped parts (130) has a nominal height (H1). The ratio of (H1) to (W1) is less than 1.
[0068] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, each of the multiple bead-shaped parts (130) is elongated.
[0069] Optionally, in the composite material structure (100) described in one of the preceding paragraphs, each of the multiple bead-shaped parts (130) includes a tapered end cap part (138) that transitions to one of the multiple base parts (140).
[0070] In other examples relating to this disclosure, the wing (170) of an aircraft is Upper exterior panel (180) and Lower outer panel (190) and Includes, At least one of the upper outer panel (180) and the lower outer panel (190) is The first layer (110), A second layer (120) is connected to the first layer (110) to form a layered structure (105), Includes, The second layer (120) is, Multiple base portions (140) that abut the first layer (110), The present invention includes a plurality of bead-shaped portions (130) protruding from a plurality of base portions (140), wherein each bead-shaped portion (130) defines a plurality of channels (135) between a first layer (110) and a second layer (120).
[0071] Optionally, the wing (170) of the aircraft described in the preceding paragraph includes at least one spar (175) positioned between the upper skin panel (180) and the lower skin panel (190).
[0072] Optionally, the aircraft wing (170) described in one of the preceding paragraphs is: At least partially, Upper exterior panel (180), Lower outer panel (190), and Spur (175) It includes a liquid-tight volume chamber (177) defined by [the specified method].
[0073] Optionally, in the wing (170) of an aircraft described in one of the preceding paragraphs, a number of channels (135) are fluidly isolated from a liquid-tight volume chamber (177).
[0074] Optionally, in the wing (170) of an aircraft described in one of the preceding paragraphs, a system feature (300) is placed within multiple channels (135).
[0075] Optionally, in the wing (170) of an aircraft described in one of the preceding paragraphs, the system feature (300) is at least one of wiring (310) and conduit (320).
[0076] Optionally, the wing (170) of an aircraft described in one of the preceding paragraphs includes at least one rib (173) positioned between an upper skin panel (180) and a lower skin panel (190).
[0077] In other examples relating to this disclosure, the method (200) for manufacturing a composite material structure (100) is: To form a second layer (120) having multiple bead-shaped parts (130) and multiple base parts (140), a tool On top of Depositing composite materials (210) In order to define channels in multiple bead-like portions (130), multiple mandrels are dispersed (220) on a second layer (120), To form the first layer (110), a composite material is deposited (230) on the second layer (120) and the plurality of mandrels, Joining the first layer (110) to the second layer (120) (240), Includes.
[0078] Optionally, in the method described in the preceding paragraph (200), dispersing multiple mandrels (220) includes dispersing multiple soluble mandrels (220).
[0079] Optionally, in the method described in one of the preceding paragraphs (200), the multiple molten mandrels include a ceramic material.
[0080] Optionally, in the method (200) of claim 29, the bonding (240) includes curing the first layer (110).
[0081] Optionally, in the method (200) described in one of the preceding paragraphs, the joining (240) includes curing an adhesive placed between the first layer (110) and the second layer (120).
[0082] Optionally, in the method (200) described in one of the preceding paragraphs, the bonding (240) includes curing the second layer (120).
[0083] In other examples relating to this disclosure, the method (200) for manufacturing a composite material structure (100) is: The process includes connecting a first layer (110) to a second layer (120) (250) in order to form a layered structure (105), Includes, The second layer (120) is, Multiple base portions (140) that abut the first layer (110), Multiple bead-shaped parts (130) protruding from multiple base parts (140), wherein each bead-shaped part (130) defines a channel (135) between a first layer (110) and a second layer (120), Includes.
[0084] Optionally, in the method described in the preceding paragraph (200), the connection (250) includes coquering the first layer (110) and the second layer (120).
[0085] Optionally, in the method described in one of the preceding paragraphs (200), the connection described above (250) is: The first layer (110) and the second layer (120) are cured separately to obtain a cured first layer (110') and a cured second layer (120'), The method includes bonding a cured first layer (110') to a cured second layer (120').
[0086] Optionally, in the method described in one of the preceding paragraphs (200), the connection described above (250) is: The first layer (110) and the second layer (120) are cured to obtain a cured layer (106) and an uncured layer (108). Applying an adhesive between the cured layer (106) and the uncured layer (108), Co-curing the adhesive and the uncured layer (108), Includes.
[0087] Various embodiments of the apparatus and methods disclosed herein include a wide variety of components, features, and functions. It should be understood that various embodiments of the apparatus and methods disclosed herein may include, in any combination, any components, features, and functions of any other embodiment of the apparatus and methods disclosed herein.
[0088] While various embodiments of the disclosed bead-like composite structure and the method for manufacturing the bead-like composite structure have been shown and described, those skilled in the art will be able to recall modifications by reading this specification. This application includes such modifications and is limited only by the claims.
[0089] Therefore, it should be understood that this disclosure is not limited to the specific embodiments illustrated, and that modifications and other embodiments are intended to be included in the appended claims. Furthermore, while the descriptions in the prior specification and the associated drawings illustrate examples of the subject matter of the invention disclosed herein in light of specific exemplary combinations of elements and / or functions, it should be understood that various combinations of elements and / or functions can be provided by alternative implementations without departing from the scope of the appended claims. Accordingly, the reference numerals enclosed in parentheses in the appended claims are provided for illustrative purposes only and are not intended to limit the scope of the subject matter of the claimed invention to the specific embodiments provided herein.
Claims
1. A composite material structure (100), The first layer (110), A second layer (120) connected to the first layer (110) to form a layered structure (105), A plurality of base portions (140) that abut against the first layer (110), and A plurality of bead-shaped portions (130) protruding from the plurality of base portions (140), wherein each of the plurality of bead-shaped portions (130) defines a channel (135) between the first layer (110) and the second layer (120). The second layer (120) includes, At least one first access opening (150) providing access to the channel (135), the at least one first access opening (150) located in at least one bead-like portion (130) of the second layer (120) and penetrating the second layer (120), On at least one base portion (140), there is at least one second access opening (150) that penetrates both the first layer (110) and the second layer (120), A composite material structure (100) including the above.
2. The composite structure (100) according to claim 1, further comprising at least one third access opening (150) providing access to the channel (135), the at least one third access opening (150) penetrating the first layer (110).
3. A composite material structure (100), The first layer (110), A second layer (120) connected to the first layer (110) to form a layered structure (105), Includes, The second layer (120) is Multiple base portions (140) that contact the first layer (110), A plurality of bead-shaped portions (130) protruding from the plurality of base portions (140), wherein each of the plurality of bead-shaped portions (130) defines a channel (135) between the first layer (110) and the second layer (120), Includes, The plurality of base portions (140) have a first nominal cross-sectional thickness (T1), The first layer (110) has a fourth nominal cross-sectional thickness (T4) in each of the plurality of base portions (140), The first layer (110) has a fifth nominal cross-sectional thickness (T5) in each of the plurality of bead-shaped portions (130), A composite material structure (100) wherein the fifth nominal cross-sectional thickness (T5) is equal to the sum of the first nominal cross-sectional thickness (T1) and the fourth nominal cross-sectional thickness (T4).
4. The composite material structure (100) according to any one of claims 1 to 3, wherein each of the plurality of bead-shaped portions (130) includes opposing side wall portions (132) and a cap portion (134) between the opposing side wall portions (132).
5. The plurality of base portions (140) have a first nominal cross-sectional thickness (T1), The opposing side wall portions (132) have a second nominal cross-sectional thickness (T2), The cap portion (134) has a third nominal cross-sectional thickness (T3), The composite material structure (100) according to claim 4, wherein the third nominal cross-sectional thickness (T3) is greater than the first nominal cross-sectional thickness (T1) and greater than the second nominal cross-sectional thickness (T2).
6. The composite material structure (100) according to claim 5, wherein the first nominal cross-sectional thickness (T1) is the same as the second nominal cross-sectional thickness (T2).
7. The plurality of base portions (140) have a first nominal cross-sectional thickness (T1), The opposing side wall portions (132) have a second nominal cross-sectional thickness (T2), The cap portion (134) has a third nominal cross-sectional thickness (T3), The composite material structure (100) according to claim 4, wherein 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 material structure (100) according to any one of claims 1 to 7, wherein the first layer (110) is not provided with bead-shaped portions (130).
9. The layered structure (105) defines a transition region (136) in which the second layer (120) transitions from one of the multiple base portions (140) to one of the multiple bead-shaped portions (130), The composite material structure (100) according to any one of claims 1 to 8, wherein the filler (155) is disposed within the transition region (136) between the first layer (110) and the second layer (120).
10. Each of the plurality of bead-shaped parts (130) has a nominal width (W1), Each of the plurality of bead-shaped parts (130) has a nominal height (H1), The composite material structure (100) according to any one of claims 1 to 9, wherein the ratio of (H1) to (W1) is less than 1.
11. A method (200) for manufacturing a composite material structure (100) according to any one of claims 1 to 10, To form the second layer (120) having the plurality of bead-shaped portions (130) and the plurality of base portions (140), the composite material is deposited on the tool (210), In order to define the channels (135) in the plurality of bead-shaped portions (130), a plurality of mandrels are dispersed (220) on the second layer (120), To form the first layer (110), a composite material is deposited (230) on the second layer (120) and the plurality of mandrels, The first layer (110) is joined to the second layer (120) (240), Method (200), including the method (200).
12. The method (200) of claim 11, wherein the dispersion (220) of the plurality of mandrels includes dispersing the plurality of soluble mandrels (220).
13. The method (200) according to claim 11 or 12, wherein the joining (240) includes curing the first layer (110).
14. The method (200) according to any one of claims 11 to 13, wherein the bonding (240) includes curing an adhesive placed between the first layer (110) and the second layer (120).
15. The method (200) according to any one of claims 11 to 14, wherein the bonding (240) includes curing the second layer (120).