US 12,319,398 B2Granted

Fabrication of multi-segment spars

AssigneeThe Boeing Company

InventorsDarrell D. Jones, Daniel R. Smith, Carlos Walker, Kurtis Shuldberg Willden, Hiteshkumar M. Patel, Jacob E. Koopmans, Scott Krajca, James P. Dobberfuhl, Marcus C. Hart, Gregory R. Klempel, Steven Kuan-Chi Wu, Justin K. Alfred

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Abstract

Systems and methods are provided for fabricating multiple segment spars for an aircraft. In one example the method includes fabricating preforms of fiber reinforced material for spar segments, hardening the preforms to form the spar segments, and bonding the spar segments together to form a completed spar detail. In addition to bonding, other examples include co-curing and fastening the spar segments. In additional examples, the spar segments include kinks or sub-kinks as described.

Claims20

Dependent claims

A method for fabricating a spar detail for an aircraft, the method comprising:

fabricating uncured preforms of fiber reinforced material for spar segments;
splicing the uncured preforms for the spar segments together end to end to form a spar detail;
after the splicing, applying a preform for a splice doubler to the spar detail that partly covers a first spar segment of the spar segments and a second spar segment of the spar segments, wherein the preform for the splice doubler is on a first side of the spar detail, wherein the first side is opposite a second side of the spar detail having a rib intersection;
and
co-curing the preform for the splice doubler with the preforms for the first spar segment and the second spar segment to form a completed spar detail;
and
wherein applying the preform for the splice doubler comprises placing the preform for the splice doubler in a position where the preform for the splice doubler extends across the rib intersection for the spar detail.

4 more elements

A method for fabricating a spar detail for an aircraft, the method comprising:

fabricating an uncured first spar segment preform of fiber reinforced material and an uncured second spar segment preform of fiber reinforced material;
splicing an end of the uncured first spar segment preform to an end of the uncured second spar segment preform to define a splice region;
after the splicing, applying at least one splice doubler preform to the splice region, wherein the at least one splice doubler preform is applied on a first side of the spar detail, wherein the first side is opposite a second side of the spar detail having a rib intersection;
and
concurrently hardening an entire assembly comprising the first spar segment preform, the second spar segment preform, and the at least one splice doubler preform to form a completed spar detail.

2 more elements

Dependencies are inferred from the claim text.

Facts

Application: 17/454,399Filed 10 Nov 2021 · us provisional application
Priority: 18 Nov 2020
Published: US 2022/0153400 A119 May 2022
Granted: 3 Jun 2025
Term ends: Not estimatedThe source records don’t support an estimate.

Classification10 codes

B64C 1/065
Frames; Stringers; Longerons ; Fuselage sections: spars
B29C 70/342
And shaping or impregnating by compression , i.e. combined with compressing after the lay-up operation: using isostatic pressure
B29C 70/44
For producing articles of definite length, i.e. discrete articles: using isostatic pressure, e.g. pressure difference-moulding, vacuum…
B29C 70/54
Shaping operations therefor: component parts, details or accessories; Auxiliary operations , e.g. feeding or storage of prepregs or SMC after…