Systems and methods are provided for integrating structural components of a wing box. One embodiment is a system that includes outboard planked stringers within an outboard section of a wing box and are co-cured with composite skin at the outboard section. Each outboard planked stringer of the outbo
Systems and methods are provided for integrating structural components of a wing box. One embodiment is a system that includes outboard planked stringers within an outboard section of a wing box and are co-cured with composite skin at the outboard section. Each outboard planked stringer of the outboard section includes planar layers of Carbon Fiber Reinforced Polymer (CFRP) that are parallel with the composite skin at the outboard section, have fiber orientations aligned to bear tension and compression applied to the wing box, and each extend a different distance along the composite skin at the outboard section. The system also includes center planked stringers within the center section and are co-cured with composite skin at the center section. Each center planked stringer of the center section includes planar layers of CFRP that are parallel with the composite skin at the center section, have fiber orientations aligned to bear tension and compression applied to the wing box, and each extend a different distance along the skin at the center section.
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1. A system comprising: outboard planked stringers that are laterally oriented within an outboard section of a wing box and are co-cured with composite skin at the outboard section,each outboard planked stringer includes planar layers of Carbon Fiber Reinforced Polymer (CFRP) that are parallel with
1. A system comprising: outboard planked stringers that are laterally oriented within an outboard section of a wing box and are co-cured with composite skin at the outboard section,each outboard planked stringer includes planar layers of Carbon Fiber Reinforced Polymer (CFRP) that are parallel with the composite skin at the outboard section, have fiber orientations aligned to bear tension and compression applied to the wing box, and each extend a different distance along the composite skin at the outboard section towards a center section of the wing box, resulting in a decrease in thickness of each outboard planked stringer, andcenter planked stringers that are laterally oriented within the center section and are co-cured with composite skin at the center section,each planked stringer of the center section includes planar layers of CFRP that are parallel with the composite skin at the center section, have fiber orientations aligned to bear tension and compression applied to the wing box, and each extend a different distance along the composite skin at the center section towards the outboard section,wherein the composite skin increases in thickness by an amount corresponding to the decrease in thickness of each outboard planked stringer, causing a combined thickness of the skin and each outboard planked stringer to remain unchanged throughout the outboard section. 2. The system of claim 1 further comprising: the composite skin at the outboard section, comprising layers of CFRP having fiber orientations aligned to bear shear stresses applied to the wing box, whereinproximate to a side of body intersection between the outboard section and the center section, layers of the composite skin at the outboard section are alternatingly overlapped with layers of the composite skin at the center section, resulting in a thickening pad-up of composite skin proximate to the side of body intersection, the thickening pad-up redirecting changes in load direction as forces are transmitted from a wing axis to a body axis. 3. The system of claim 2 wherein: each layer of the composite skin at the outboard section overlaps a layer of the composite skin at the center section by a different amount, resulting in an incrementally changing amount of overlap as distance to the side of body intersection changes. 4. The system of claim 2 wherein: the thickening pad-up of composite skin results from an increase in a number of layers of composite skin proximate to the side of body intersection, increasing skin thickness between twenty and two hundred percent gage at the thickening pad-up. 5. The system of claim 2 wherein: the thickening pad-up of composite skin proximate to the side of body intersection includes layers having fiber orientations that follow a wing axis of an aircraft, and layers having fiber orientations that follow a body axis of the aircraft. 6. The system of claim 1 wherein: a thickness of each of the outboard planked stringers tapers down between forty and one hundred percent as the planked stringer extends towards a side of body intersection between the outboard section and the center section. 7. The system of claim 6 wherein: a combination of the outboard planked stringers and the composite skin at the outboard section tapers down at a ramp rate between 2000:1 and 10:1. 8. The system of claim 7 wherein: the combination of the outboard planked stringers and the composite skin at the outboard section tapers down at a ramp rate of 100:1. 9. The system of claim 1 wherein: the composite skin at the outboard section mechanically couples the outboard planked stringers to the center planked stringers. 10. The system of claim 1 wherein: each outboard planked stringer is a different length. 11. The system of claim 1 wherein: for each outboard planked stringer, adjacent layers extend incrementally different distances along the composite skin at the outboard section towards the center section. 12. A method comprising: laying up outboard planked stringers that are laterally oriented within an outboard section of a wing box, each outboard planked stringer including planar layers of Carbon Fiber Reinforced Polymer (CFRP) that are parallel with composite skin at the outboard section, have fiber orientations aligned to bear tension and compression applied to a wing, and each extend a different distance along the composite skin at the outboard section towards a center section of the wing, resulting in a decrease in thickness of each outboard planked stringer;laying up center planked stringers that are laterally oriented within the center section of the wing, each center planked stringer including planar layers of CFRP that are parallel with composite skin at the center section, have fiber orientations aligned to bear tension and compression applied to the wing, and each extend a different distance along the composite skin at the center section towards the outboard section of the wing; andco-curing the outboard planked stringers to the composite skin at the outboard section, and center planked stringers to the composite skin at the center section, wherein the composite skin increases in thickness by an amount corresponding to the decrease in thickness of each outboard planked stringer, causing a combined thickness of the skin and each outboard planked stringer to remain unchanged throughout the outboard section. 13. The method of claim 12 further comprising: laying up the composite skin at the outboard section and the composite skin at the center section,wherein laying up comprises alternatingly overlapping, proximate to a side of body intersection between the outboard section and the center section, layers of the composite skin at the center section and layers of the composite skin at the outboard section, resulting in a thickening pad-up of composite skin proximate to the side of body intersection, the thickening pad-up redirecting changes in load direction as forces are transmitted from a wing axis to a body axis. 14. The method of claim 13 wherein: laying up comprises adjusting an overlap amount with each layer of the composite skin at the outboard section and each layer of the composite skin at the center section, resulting in an incrementally changing amount of overlap as distance to the side of body intersection changes. 15. The method of claim 13 wherein: the thickening pad-up of composite skin results from an increase in a number of layers of composite skin proximate to the side of body intersection, increasing skin thickness between twenty and two hundred percent gage at the thickening pad-up. 16. The method of claim 13 wherein: laying up includes laying up layers of composite skin having fiber orientations that follow a wing axis of an aircraft, and laying up layers of composite skin having fiber orientations that follow a body axis of the aircraft. 17. The method of claim 12 wherein: laying up the outboard planked stringers comprises tapering down a thickness of each outboard planked stringer between forty and one hundred percent as the outboard planked stringer extends towards a side of body intersection between the outboard section and the center section. 18. The method of claim 17 wherein: a combination of the outboard planked stringers and the composite skin at the outboard section tapers down at a ramp rate between 2000:1 and 10:1. 19. The method of claim 18 wherein: the combination of the outboard planked stringers and the composite skin at the outboard section tapers down at a ramp rate of 100:1. 20. The method of claim 12 wherein: the composite skin at the outboard section mechanically couples the outboard planked stringers to the center planked stringers.
Cruz Domínguez, Francisco José; García Nieto, Carlos; Honorato Ruiz, Francisco Javier, Composite structure for an aircraft and manufacturing method thereof.
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