Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Patent
1983-06-06
1986-01-21
Ball, Michael
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
156172, 156182, 156245, 244123, 264258, B64C 318, B32B 500
Patent
active
045655952
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
The high strength to weight ratio of composite components make the composites attractive for use on airplanes. However, the joints between composite components involve one of the most difficult problems of adapting the composites to the manufacture of airplanes. These problems are severely multiplied when the joints are highly stressed in several directions. It was found that a composite skin-spar joint could be prepared that not only lends itself to providing a low weight high strength joint for any composite, but it is particularly attractive for use in aircraft wings. The joint when integrated makes spars that carry the loads without the need for ribs.
SUMMARY OF THE INVENTION
A composite aircraft wing has an integral skin-spar joint that has a resin impregnated interwoven fabric with a pair of spaced apart spanwise extending panels, and a bisecting laterally extending interwoven panel that extends laterally to each side. Three cores are joined to one side of the laterally extending panel. The intermediate core extends between and is joined to the spaced apart panels, and has directional reinforcement to handle torsional loads. The other two cores have reinforcement to handle varying loads in a spanwise direction. A fourth core is located adjacent to the intermediate core and is joined to the three panels. The skin-spar joints in combination with a honeycomb core are used to make up spars for a composite aircraft wing. The wing is formed with a series of shaped mandrels each wrapped with reinforced plastic and the mandrels aligned in spaced relation one above the other with spar materials between mandrels, and honeycomb core and reinforced plastic skins alongside the mandrels all curved into a composite wing.
DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a cross-sectional end view of the buildup of the composite wing of this invention mounted in a mold.
FIG. 2 shows cross-sectional end views of various stages of buildup of the wing of FIG. 1.
FIG. 3 shows a blow up of a fragmented section of the wing of FIG. 1.
FIG. 4 shows a fragmented view of a further blowup of FIG. 3 showing more detail of the skin-spar joint of this invention.
FIGS. 5 and 6 are perspective views showing the layup of wing skins for this invention.
FIG. 7 is a cross-sectional view taken along lines 7--7 of FIG. 6 and showing the covered mandrel in a mold and ready for curing.
FIG. 8 is a blown up fragmented view of FIG. 7.
FIGS. 9 and 10 are perspective views showing the layup of reinforced plastic on a mandrel for the cell liner of a wing.
FIG. 11 is a cross-sectional view taken along lines 11--11 of the mandrel of FIG. 10.
FIG. 12 shows a schematic plan view of the spars of the composite aircraft wing.
FIG. 13 is a graph showing the wing bending movement for the wing of FIG. 12.
FIG. 14 shows a side elevational view of one of the chords, without a cover layer, making up a skin-spar joint.
FIG. 15 is a cross-sectional view taken along line 15--15 of FIG. 14.
FIG. 16 shows a cross-sectional side elevational view of skin-spar joints in a wing of an aircraft.
DETAILED DESCRIPTION
Composite skin-spar joint 10, is made up of resin impregnated interwoven fabric 12, cores 14, and 16, and chords 18a and 18b.
The interwoven fabric 12 is prepared from any of the known reinforcing fibers such as, but not limited to, fiberglass and graphite, and will be impregnated with any of the known resins, such as but not limited to, phenolic or epoxy resin. The impregnated fabric extends for the length of the desired span for the joint, is essentially H-shaped in cross section, and has fiber orientation that is predominately transverse. The fabric has a panel 20 that extends laterally and is bisected at 22a and 22b where it is interwoven with a pair of spaced apart panels 24a and 24b. The two spaced apart panels preferably have the spacing increase as the panels extend outward.
Core 14 is directly in contact with all three layers of the fabric, is located in the web area, and is preferably of a honeycomb material. A plasti
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Ball Michael
Case Morris A.
Donahue Bernard A.
The Boeing Company
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