The Boeing Company

Robert D Biornstad

William H Ingram

Bruce C Blankinship

Terry J George

Kenneth Marvin Dull

William Henry Ingram, Jr

Jr William H Ingram

William H Ingram Jr

A method for fabricating a one-piece composite fuselage section that minimizes out-of-plane fiber distortion. This is accomplished by fabricating a mandrel having a coefficient of thermal expansion in the hoopwise direction that is sufficiently greater than that of the laid-up composite ply assembly. As a result of this differential in the coefficients of thermal expansion in the hoopwise direction, the laid-up composite ply assembly is stretched circumferentially as the mandrel expands radially during cure, thereby eliminating or reducing out-of-plane fiber distortion. At the same time, the mandrel and part being fabricated should have substantially the same coefficient of thermal expansion in the lengthwise direction. As the outer surface of the mandrel increases in circumference, the circumferentially oriented reinforcing fibers of the inner plies are stretched, while the circumferentially oriented reinforcing fibers of the outer plies do not reduce in circumference and thus do not form waves or wrinkles.

Method for minimizing fiber distortion during fabrication of one-piece composite barrel section

Composite sections for aircraft fuselages and methods and systems for manufacturing such sections are herein. A composite aircraft panel manufacturing assembly comprises a skin, a stiffener, a tubular bladder, and at least one ply of fabric. The stiffener comprises first and second flange portions bonded to the skin. The stiffener further comprises an interior surface, spaced apart from the skin, and extending between the first and second flange portions. The tubular bladder extends longitudinally between the interior surface of the stiffener and the skin. The at least one ply of fabric extends around the bladder and is bonded to the interior surface of the stiffener and an adjacent portion of the skin between the first and second flange portions.

Composite barrel sections for aircraft fuselages and other structures

Composite sections for aircraft fuselages and methods and systems for manufacturing such sections are disclosed herein. A composite section configured in accordance with one embodiment of the invention includes a skin and at least first and second stiffeners. The skin can include a plurality of unidirectional fibers forming a continuous surface extending 360 degrees about an axis. The first stiffener can include a first flange portion bonded to an interior surface of the skin and a first raised portion projecting inwardly and away from the interior surface of the skin. The second stiffener can include a second flange portion bonded to the interior surface of the skin and a second raised portion projecting inwardly and away from the interior surface of the skin. A method for manufacturing a section of a fuselage in accordance with one embodiment of the invention includes positioning a plurality of uncured stiffeners on a mandrel assembly. The method can further include applying a plurality of fiber tows around the plurality of uncured stiffeners on the mandrel assembly.

Composite barrel sections for aircraft fuselages and other structures, and methods for systems for manufacturing such barrel sections

Composite barrel sections for aircraft fuselages and other structures, and methods and systems for manufacturing such barrel sections

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Renton, WA, United States of America

Robert D Biornstad