Contoured composite stringers

• Main Authors: Jones, Darrell D, Rotter, Daniel, Kwon, Hyukbong, Coxon, Brad Andrew, Pham, Khanh Mai, Robins, Brian, Carlson, Lisa
• Format: Patent
• Language: English
• Published: 30.05.2023
• Subjects: AEROPLANES; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING; AIRCRAFT; AVIATION; COSMONAUTICS; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING ORREPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLYADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFTCOMPONENTS, NOT OTHERWISE PROVIDED FOR; HELICOPTERS; INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULARARTICLES; INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS; PERFORMING OPERATIONS; PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCESIN A PLASTIC STATE; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDEDFOR; SHAPING OR JOINING OF PLASTICS; TRANSPORTING; WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE, IN GENERAL

Aircraft that incorporates a rounded-hat composite stringer connected to an inner side of the skin of the aircraft to form an elongate conduit that defines a conduit axis, where the conduit axis includes at least one curving portion. The rounded-hat composite stringer can be manufactured by constructing a lower forming die and an upper forming die, each forming die having a length and defining a curve along at least a portion of the length of the die, cutting a pre-cured flat composite charge dimensioned to form the rounded-hat composite stringer, pressing the flat composite charge between the lower and upper forming dies to shape the composite charge into a pre-formed stringer having an inner side between curved fillet portions, contacting a forming member against the inner side of the pre-formed stringer, applying radius fillers to the curved fillet portions of the pre-formed stringer, curing the pre-formed stringer, and removing the forming member from the cured stringer.