Method of forming a reinforced foam-filled composite stringer
AssigneeThe Boeing Company
InventorsSimon D. Senibi, Barry P. Van West, Juan Carlos Guzman, Douglas A. McCarville, Daniel M. Rotter
Life of this patent
Estimating the term…
Abstract
A method and apparatus for manufacturing a composite stringer. A composite material and foam are laid up onto a tool in the form of a stringer. The foam has a plurality of structural members within the foam. The plurality of structural members has a number of orientations to resist a number of loads. The composite material, the foam in the form of the stringer, and the plurality of structural members are cured to form the composite stringer.
Claims18
A method for manufacturing a composite stringer, the method comprising:
- placing a plurality of structural members within a foam, the plurality of structural members comprising at least one of a number of pins, a number of tubes, and a number of rods;
- laying up a composite material and the foam with the plurality of structural members within the foam onto a tool in the form of a stringer, wherein the plurality of structural members has at least a first orientation and a second orientation, the first orientation and the second orientation being different from each other, the plurality of structural members configured to resist a number of loads on the stringer including at least compressive loads;
- placing the foam and the composite material onto a skin ply such that the plurality of structural members within the foam do not substantially pierce the skin ply;
- wherein the structural members extend from the skin ply to a first and a second wall of the composite stringer and wherein the structural members are positioned substantially within the foam;
- and
- curing the composite material, the foam in the form of the stringer, and the plurality of structural members to form the composite stringer.
A method for forming a composite part, the method comprising:
- laying up a composite material and a foam core onto a tool in a form of the composite part, the foam core having a plurality of structural members, wherein the plurality of structural members has at least a first orientation and a second orientation, the first orientation and the second orientation being different from each other, the plurality of structural members configured to resist a number of loads including at least compressive forces on the composite part, the plurality of structural members comprising at least one of a number of pins, a number of tubes, and a number of rods;
- placing the foam core and the composite material onto a skin ply;
- curing the composite material and the foam core in the form of the composite part such that the plurality of structural members do not substantially pierce the skin ply;
- wherein the structural members extend from the skin ply to a first and a second wall of the composite part stringer and wherein the structural members are positioned substantially within the foam;
- and
- forming the composite part with a channel in which the foam core is located.
A method for manufacturing a plurality of composite stringers, the method comprising:
- laying up composite material and foam with a plurality of z-pins within the foam onto a plurality of tools to form a plurality of composite stringers, wherein the plurality of z-pins has at least a first orientation, the plurality of z-pins configured to resist a number of loads including compressive loads on the composite stringers, and the plurality of z-pins comprising at least one of a number of pins, a number of tubes, and a number of rods;
- placing the plurality of composite stringers on a single tool;
- placing a skin ply over the plurality of composite stringers to form a structure;
- wherein the plurality of z-pins extends from the skin ply to a first and a second wall of the composite stringers and wherein the structural members are positioned substantially within the foam;
- and
- curing the structure such that the plurality of z-pins do not substantially extend past the first and the second wall of the composite stringer.
Dependencies are inferred from the claim text.