# US 2014/0197271 A1 · Helicopter

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 2014/0197271 A1
- Document ID: US20140197271A1
- Status: Published application
- Kind: A1
- Application number: 14/124,247
- Filed: 2012-06-07
- Published: 2014-07-17
- Earliest claimed: 2011-06-07
- Assignees: Composite Helicopter Holdings Limited
- Inventors: Peter Maloney; Nina Heatley
- Web page: https://patentgrep.com/patent/US20140197271A1

## CPC

- B29C 66/30325: {making use of cavities belonging to at least one of the parts to be joined}
- B64D 37/04: Arrangement thereof in or on aircraft
- B29C 65/483: {Reactive adhesives, e.g. chemically curing adhesives}
- B29C 65/52: {characterised by the way of} applying the adhesive {(B29C65/50 takes precedence; apparatus for applying liquids in general B05C; processes for applying liquids in general B05D)}
- B29C 65/605: {the rivets being molded in place, e.g. by injection}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/532: {Joining single elements to the wall of tubular articles, hollow articles or bars}
- B29C 66/54: {Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles}
- B29C 66/543: {joining more than two hollow-preforms to form said hollow articles}
- B29C 66/545: {one hollow-preform being placed inside the other}
- B29C 66/721: {Fibre-reinforced materials (B29C66/729 takes precedence)}
- B29C 66/72141: {Fibres of continuous length}
- B29C 70/304: {In-plane lamination by juxtaposing or interleaving of plies, e.g. scarf joining}
- B29C 70/443: {and impregnating by vacuum or injection}
- B60N 2/4242: {vertical}
- B60N 2/42709: {involving residual deformation or fracture of the structure}
- B60N 2/686: {Panel like structures}
- B64C 1/00: Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
- B64C 27/04: Helicopters
- B64C 27/82: characterised by the provision of an auxiliary rotor or fluid-jet device for counter-balancing lifting rotor torque or changing direction of rotorcraft
- B64D 11/0619: {with energy absorbing means specially adapted for mitigating impact loads for passenger seats, e.g. at a crash}
- B64D 11/0689: {specially adapted for pilots}
- B29C 66/61: {Joining from or joining on the inside (for making tubes by bending sheets and joining from the inside B29C53/387)}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/7212: {characterised by the composition of the fibres}
- B29C 66/727: {being porous, e.g. foam}
- B29L 2031/3082: {Fuselages}
- B29L 2031/3088: {Helicopters}
- B29L 2031/7172: {Fuel tanks, jerry cans}
- B29L 2031/771: {Seats}
- B64C 2027/8254: {Shrouded tail rotors, e.g. "Fenestron" fans}
- Y02T 50/40: Weight reduction
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B64D: EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENT OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
- B60N: SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
- B64C: AEROPLANES; HELICOPTERS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION

## Abstract

A composite structure forming a load bearing composite shell for a helicopter, with a shell which defines the exterior of a fuselage and includes a central fuselage section and tail boom, a fuselage which is adapted house an engine or drive train, a layered composite crashworthy seat and support structure and a fastening and a method of fastening by providing an adhesive between two layers which is allowed to flow through opposing holes in the layers to provide a chemical and mechanical attachment between the layers.

## Claims

### Claim 1

A primary flight structure comprising:
a load bearing composite shell defining at least the exterior of a helicopter fuselage, the fuselage defining at least a central fuselage section and tail boom,
wherein the central fuselage section is adapted enclose at least one of an engine or drive train.

### Claim 2 (depends on 1)

A primary flight structure as claimed in claim 1, wherein the tail boom has attached or is adapted to have attached at least one of an empennage, fins, or tail rotor mechanism.

### Claim 3 (depends on 1)

A primary flight structure as claimed in claim 1, wherein the empennage is adapted to support a ducted fan tail rotor assembly, horizontal and vertical stabilisers.

### Claim 4 (depends on 1)

A primary flight structure as claimed in claim 1, wherein the tail boom is adapted to have attached an empennage to thereby form a monocoque structure.

### Claim 5 (depends on 1)

A primary flight structure as claimed in claim 1, further comprising a forward section of the fuselage adapted to house one or more occupants and flight controls.

### Claim 6 (depends on 1)

A primary flight structure as claimed in claim 1, wherein the central section and forward section of the fuselage delineates at least one of a door, window or hatch opening.

### Claim 7 (depends on 1)

A primary flight structure as claimed in claim 1, wherein the structure delineates an opening located in an upper region of the fuselage surface, the opening adapted to allow at least one of an engine or main rotor gearbox or drive train module to be at least partly inserted into the fuselage.

### Claim 8 (depends on 1)

A primary flight structure as claimed in claim 1, further comprising at least two members components extending between at least an upper and lower internal surface of the fuselage.

### Claim 9 (depends on 8)

A primary flight structure as claimed in claim 8, wherein the members provide at least one attachment point for at least one of an engine or main rotor gearbox or drive train module, or at least one attachment point for a frame assembly to which at least one of an engine or main rotor gearbox or drive train module are adapted to be attached.

### Claim 10 (depends on 8)

A primary flight structure as claimed in claim 8, further comprising at least two members extending at least between side internal surfaces of the fuselage and transversely to the at least two members extending between at least an upper and lower internal surface of the fuselage.

### Claim 11 (depends on 10)

A primary flight structure as claimed in claim 10, wherein at least one of the members is adapted to transfer load created by at least one of an engine or main rotor gearbox or drive train module to the composite shell.

### Claim 12 (depends on 10)

A primary flight structure as claimed in claim 10, wherein at least one of the members is arranged to at least partially create an enclosed space in which one or more fuel cells can be located.

### Claim 13 (depends on 10)

A primary flight structure as claimed in claim 10, wherein the members are adapted to create a structure attachable to the internal surface of the composite shell such that the structure least partially absorbs aircraft impact energy and diverts energy away from the enclosed space.

### Claim 14 (depends on 10)

A primary flight structure as claimed in claim 10, wherein at least two members further comprise an integrally formed and forward protruding substructure adapted to extend from the central fuselage section to the forward section, the protruding substructure having a lower region adapted to attach to a lower internal surface of the composite shell and an upper region adapted to support a cabin floor panel.

### Claim 15 (depends on 14)

A primary flight structure as claimed in claim 14, wherein the forward section of the fuselage and the cabin floor panel at least partly define a cabin space such that seating for occupants and flight controls can be located or referenced.

### Claim 16 (depends on 14)

A primary flight structure as claimed in claim 14, wherein the cabin floor is supported by the forward protruding member and a plurality of structural members, the structural members adapted to extend between the lower side of the cabin floor panel and the internal surface of the lower region of the composite shell.

### Claim 17 (depends on 16)

A primary flight structure as claimed in claim 16, wherein the structural members are adapted to attach to the cabin floor panel and the internal surface of the composite shell.

### Claim 18 (depends on 16)

A primary flight structure as claimed in claim 16, wherein the structural members comprise a first set of members and second set or members and the first set of members are adapted to extend substantially perpendicular to the second set of members such that the structural members together, when combined, are adapted to form a lattice structure extending between the cabin floor panel and the internal surface of the composite shell.

### Claim 19

(canceled)

### Claim 20 (depends on 1)

A primary flight structure as claimed in claim 1, wherein the composite shell comprises a laminate, the laminate comprising a plurality of fabric layers.

### Claim 21 (depends on 20)

A primary flight structure as claimed in claim 20, wherein the plurality of fabric layers comprise a first layer of continuous filament mat, a first layer of carbon and Kevlar composite, a layer of unidirectional carbon fibre, a second layer of carbon and Kevlar composite, a second layer of continuous filament mat and wherein the laminate is, or is adapted to be infused with a cured or curable resin.

### Claim 22 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the laminate further comprises additional laminates and/or core filler material including Soric.

### Claim 23 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the laminate further comprises a layer of carbon unidirectional fabric between the first and second layers.

### Claim 24 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the laminate further comprises a layer of carbon double bias fabric between the first and second layers.

### Claim 25 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the laminate further comprises a filler layer between the first and second layers.

### Claim 26 (depends on 24)

A primary flight structure as claimed in claim 24, wherein the layer of carbon double bias fabric comprises a plurality of layers of carbon double bias fabric, including:
a plurality of layers that span a surface of an upper region of the central fuselage section to a surface of an upper section of the tail boom,
a plurality of layers that span the upper region of the central fuselage surface section to a middle and a lower surface section of the tail boom, and
a plurality of layers that span between a lower region of the central fuselage section to at least some way into the lower surface of the tail boom region.

### Claim 27 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the unidirectional carbon fibre fabric is approximately 200 g/mm2.

### Claim 28 (depends on 21)

A primary flight structure as claimed in claim 21, wherein at least some of the support fabrics are approximately 200 mm to 300 mm wide.

### Claim 29 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the support fabrics are integrated within the laminate layers of the fuselage, and/or the continuous filament mat layers are approximately 300 g/mm2.

### Claim 30 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the carbon and Kevlar composite layers are approximately 190 g/mm2.

### Claim 31 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the filler layer is approximately 2 mm thick.

### Claim 32 (depends on 21)

A primary flight structure as claimed in claim 21, wherein the outer surface layer is formed as a substantially smooth and substantially continuous surface that extends through at least the central fuselage section to the tail boom.

### Claim 33

An enclosure for a primary flight structure for a helicopter adapted to provide protection for one or more fuel cells, the enclosure comprising at least four upstanding panel members spanning between an upper and lower internal surface of a substantially enclosed composite fuselage or outer shell of a flight structure, at least two panel members having a surface extending laterally relative to the interior of the fuselage or outer shell of the flight structure interior and attaching to the internal surface of the fuselage at least in an upper and lower region thereof, and at least two panel members extending longitudinally to the interior of the fuselage or outer shell of a flight structure interior and attaching to the interior surface of the fuselage at least in an upper and lower region thereof, the panel members defining an enclosed space.

### Claim 34 (depends on 33)

An enclosure as claimed in claim 33, wherein each of the fuselage or outer shell and panel members comprise a composite laminate structure.

### Claim 35 (depends on 33)

An enclosure as claimed in claim 33, further comprising a floor member attached to a lower region of the enclosed space.

### Claim 36 (depends on 33)

An enclosure as claimed in claim 33, wherein the upper region of the panel members is adapted to support at least one of an engine or main rotor gearbox or drive train module, or at least a frame assembly to which at least one of an engine or main rotor gearbox or drive train module are attachable.

### Claim 37 (depends on 33)

An enclosure as claimed in claim 33, wherein the enclosure is adapted to support at least one fuel cell.

### Claim 38 (depends on 33)

An enclosure as claimed in claim 33, wherein at least one of the panel members has an aperture through which a fuel cell can be inserted.

### Claim 39 (depends on 33)

An enclosure as claimed in claim 33, wherein the fuselage or outer shell and panel members together form a structure such that, when subjected to an impact load, divert impact energy away from the enclosed space.

### Claim at position 40

40-132. (canceled)