Composite doors and methods of forming thereof

Abstract

Disclosed is a method of forming a composite door. A precursor frame sheet, comprising flaps, is formed by cutting a prepreg sheet. The precursor frame sheet is draped over a door-forming tool, comprising a frame face and flap supports, non-parallel to the frame face, such that each of the flaps of the precursor frame sheet is geometrically complementary with a corresponding one of the flap supports. A composite frame is formed by curing the precursor frame sheet, draped over the door-forming tool, wherein the composite frame comprises a first rail and a second rail. The composite frame is separated from the door-forming tool. The composite frame, first composite edge fittings, second composite edge fittings, a first composite side beam, a second composite side beam, and a composite skin are interconnected. The first composite side beam comprises a first-beam base and two first-beam sides, non-parallel to the first-beam base, and connecting the first composite side beam to the composite frame comprises connecting a first one of the two first-beam sides to the first rail.

Dependencies are inferred from the claim text.