Co-cured composite structures and method of making them

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally,
• each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, wherein
• each hollow mandrel is formed of a unitary stiffened carbon fabric tape and wherein
• the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material,
• at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers, each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, with each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers,
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and
• wherein
• the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• at least one of the stiffener/spacer composite members is tubular with the side walls joined by at least one of the base walls.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material,
• at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers, each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, with each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers,
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and
• wherein
• the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• each hollow mandrel is formed of a unitary stiffened carbon fabric tape.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers, each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, with each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein
• the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• at least one of the stiffener/spacer composite members is of non-uniform cross section along at least a portion of its length.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• both of the stiffener/spacer composite members are of non-uniform cross section along at least portions of their lengths.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• at least a portion of one of the stiffener/spacer composite members has a longitudinal axis that is curved.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• wherein the width of at least one of the base walls of one of the stiffener/spacer composite members varies along at least a portion of its length.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• the heights of the side walls of at least one of the stiffener/spacer composite members are different along at least portions of their lengths.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• the height of at least one of the side walls of one of the stiffener/spacer composite members varies along at least a portion of its length.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• the stiffener/spacer members converge longitudinally along a least portions of their lengths.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• at least one of the skin layers is curved along at least a portion of its longitudinal extent.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• at least one of the skin layers is curved along at least a portion of its lateral extent.

A composite structure comprising

• first and second composite skin layers, each of a resin-impregnated fiber material, at least two elongated stiffener/spacer composite members, each of a resin-impregnated fiber material and interposed between the skin layers,
• each stiffener/spacer composite member being arranged generally longitudinally of the skin layers and the stiffener/spacer composite members being spaced apart laterally, each stiffener/spacer composite member having side walls extending between and united with the skin layers by base walls bonded to the inner faces of the skin layers, and
• an elongated hollow mandrel of a stiffened fabric received between and in engagement with the side walls of the of the stiffener/spacer composite member, and wherein the composite skin layers and stiffener/spacer composite members are co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary, and
• the top and bottom skin layers meet and are in engagement at a longitudinal edge juncture and the composite structure further comprises an elongated composite member of wedge-shape in cross section and of a resin-impregnated fiber material received between and engaged with portions of the top and bottom skin layers adjacent the edge juncture.