초록 ▼

Composite honeycomb core structures, such as airplane control surface structures, capable of withstanding bending and shear stresses, are disclosed along with a single stage hot bonding process of manufacturing such structures. The composite structures include: a primary load carrying member formed

Composite honeycomb core structures, such as airplane control surface structures, capable of withstanding bending and shear stresses, are disclosed along with a single stage hot bonding process of manufacturing such structures. The composite structures include: a primary load carrying member formed of a high density honeycomb core, two spar caps, each having a predetermined thickness, bonded to opposing surfaces of the high density honeycomb core; a low density honeycomb core bonded to the high density honeycomb core along one edge thereof; and, a skin superposed on, and bonded to, the spar caps and the low density honeycomb core. (In some cases, depending upon the structural strength needed, the high density honeycomb core may be replaced by a low density honeycomb core and formed in a unitary manner with the low density honeycomb core to which the skin is bonded. Or, both can be high density honeycomb cores formed in a unitary manner and machined to the desired shape.) The single stage hot bonding process includes the steps of bonding a low density honeycomb core to a high density honeycomb core, shaping the combined honeycomb core, adhesively attaching spar caps to opposing surfaces of the high density honeycomb core, adhesively attaching a skin to the spar caps and the low density honeycomb core and curing the composite structure in a heated bag mold.

대표청구항 ▼

An airplane control surface structure comprising: (a) a primary load carrying member comprising an elongate honeycomb core and first and second spar caps bonded to opposing edges of said elongate honeycomb core, said elongate honeycomb core being continuous in the direction extending between said fi

An airplane control surface structure comprising: (a) a primary load carrying member comprising an elongate honeycomb core and first and second spar caps bonded to opposing edges of said elongate honeycomb core, said elongate honeycomb core being continuous in the direction extending between said first and second spar caps, said elongate honeycomb core and said first and second spar caps bearing the major portion of the shear stress applied to said airplane control surface structure; (b) an airplane control surface defining honeycomb core affixed to one side of said primary load carrying member such that a predetermined average discontinuity exists between adjacent surfaces of said primary load carrying member and said control surface defining honeycomb core with said control surface defining honeycomb core exceeding in height said primary load carrying member, said control surface defining honeycomb core having an outer surface that defines the trailing edge region of an airplane control surface; (c) a skin superimposed over and bonded to the outer surface of said airplane control surface defining honeycomb core and said spar caps; and, (d) a leading edge affixed to said spar caps on the side of said primary load carrying member opposed to the side affixed to said airplane control surface defining honeycomb core.