# US 8,784,596 B2 · Method for making and joining composite sandwich shell edge joint > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,784,596 B2 - Document ID: US8784596B2 - Status: Granted - Kind: B2 - Application number: 12/950,191 - Filed: 2010-11-19 - Published: 2012-05-24 - Granted: 2014-07-22 - Earliest claimed: 2010-11-19 - Assignees: The Boeing Company - Applicants: Michael Leslie Hand; Douglas A. McCarville; Juan Carlos Guzman - Inventors: Michael Leslie Hand; Douglas A. McCarville; Juan Carlos Guzman - Web page: https://patentgrep.com/patent/US8784596B2 ## CPC - B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs - B29C 66/5221: {for forming coaxial connections, i.e. the tubular articles to be joined forming a zero angle relative to each other} - B29C 66/5241: {for forming coaxial connections, i.e. the profiled elements to be joined forming a zero angle relative to each other} - B29C 66/721: {Fibre-reinforced materials (B29C66/729 takes precedence)} - B29C 66/72523: {multi-channelled or multi-tubular (B29C66/438, B29C66/5227 take precedence)} - B32B 38/1866: {conforming the layers or laminate to a convex or concave profile} - Y10T 403/553: Laterally inserted section - 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) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method for joining fittings to a composite sandwich shell edge includes laying up an inner facesheet and positioning a wrapped flute mandrel on top; applying a layer of adhesive on the inner facesheet and positioning spacer-supported fittings on top; applying adhesive over the co-bonded fittings and laying up an outer facesheet forming an assembly; curing the assembly under heat and pressure; removing the fittings by first collapsing the spacers and removing the flute mandrel; placing an adhesive layer on the fittings with collapsible spacers inserted therein; reinserting the fittings between the inner and outer facesheets and effecting bonding and curing; and removing the spacers from the fittings by collapsing the spacers. ## Claims ### Claim 1 A method for forming a fitting, comprising: placing an inboard ply stack in a cavity of a first die, the inboard ply stack having a first portion tapered in thickness towards a first peripheral edge of the inboard ply stack and a second portion tapered in thickness towards a second peripheral edge of the inboard ply stack; positioning a collar tool having a pocket on the inboard ply stack such that: a first portion of the collar tool tapered in thickness towards a first inner edge defining the pocket is in alignment with the first portion of the inboard ply stack; and a second portion of the collar tool tapered in thickness towards a second inner edge defining the pocket is in alignment with the second portion of the inboard ply stack, the second inner edge extending perpendicular to the first inner edge; placing a bridge ply stack in the pocket of the collar tool in contact with the inboard ply stack; placing an outboard ply stack on the bridge ply stack such that a first portion of the outboard ply stack is in alignment with the first portion of the collar tool; positioning a second die on the outboard ply stack; and curing the inboard ply stack, the bridge ply stack and the outboard ply stack to form a fitting having the bridge ply stack positioned between the inboard ply stack and the outboard ply stack, the inboard ply stack and the outboard ply stack being spaced apart via the bridge ply stack. ### Claim 2 (depends on 1) The method according to claim 1, wherein the inboard ply stack is to form an inboard buildup pad of a joint body and the outboard ply stack is to form an outboard buildup pad of the joint body. ### Claim 3 (depends on 1) The method according to claim 1, further comprising providing a bolt opening in the inboard and outboard buildup ply stacks and the bridge ply stack. ### Claim 4 (depends on 1) The method according to claim 1, wherein curing the inboard ply stack, the bridge ply stack and the outboard ply stack comprises co-curing and co-bonding the inboard ply stack, the bridge ply stack and the outboard ply stack together between the first and second dies. ### Claim 5 (depends on 1) The method according to claim 1, further comprising combining an inboard facesheet on the inboard ply stack, and combining an outboard facesheet on the outboard ply stack. ### Claim 6 (depends on 1) The method according to claim 1, further comprising curing the inboard ply stack, the bridge ply stack and the outboard ply stack at a temperature between about 200° F. and about 400° F. ### Claim 7 (depends on 1) The method according to claim 1, further comprising curing the inboard ply stack, the bridge ply stack and the outboard ply stack at a pressure between about 100 psi and about 500 psi. ### Claim 8 (depends on 1) The method according to claim 1, wherein positioning the collar tool on the inboard ply stack comprises aligning the first peripheral edge of the inboard ply stack with a fourth peripheral edge of the collar tool, the third portion of the collar tool including the fourth peripheral edge. ### Claim 9 (depends on 1) The method according to claim 1, wherein the first portion of the outboard ply stack is tapered in thickness towards a first peripheral edge of the outboard ply stack. ### Claim 10 (depends on 9) The method according to claim 9, wherein a second portion of the outboard ply stack is tapered in thickness towards a second peripheral edge of the outboard ply stack. ### Claim 11 A method, comprising: placing a first buildup pad in a cavity of a first die, the first buildup pad being thickest at a first portion, the first buildup pad thickness tapering in a first direction from the first portion towards a first peripheral edge of the first buildup pad; positioning a collar tool in contact with the first buildup pad such that a pocket defined by inner edges of the collar tool is aligned with the first portion of the buildup pad; placing a bridge ply stack in the pocket of the collar tool such that the bridge ply stack is in contact with the first portion of the first buildup pad; placing a second buildup pad stack on the collar tool such that a first portion of the second buildup pad is in contact with the bridge ply stack, the second buildup pad being thickest at the first portion of the second buildup pad, the second buildup pad thickness tapering in the first direction from the second portion towards a first peripheral edge of the second buildup pad; and forming a fitting including the first buildup pad, the second buildup pad, and the bridge ply stack, the fitting having the bridge ply stack positioned between the first and second buildup pads. ### Claim 12 (depends on 11) The method according to claim 11, the first buildup pad thickness tapering in a second direction from the first portion towards a second peripheral edge of the first buildup pad. ### Claim 13 (depends on 12) The method according to claim 12, wherein the first peripheral edge of the first buildup pad is perpendicular to the second peripheral edge of the first build pad. ### Claim 14 (depends on 12) The method according to claim 12, the second buildup pad thickness tapering in the second direction from the second portion toward a second peripheral edge of the second buildup pad. ### Claim 15 (depends on 14) The method according to claim 14, wherein the second peripheral edge of the second buildup pad is perpendicular to the second peripheral edge of the second buildup pad.