Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: Methods for manufacturing composite sections for aircraft fuselages and other structures are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: A bonded composite joint may include a base having a foot configured to couple to a member. The base may include a flange extending outward from the foot. The joint further may include a panel having a core positioned between opposing skins, where the skins have inner walls proximate the core and the skins extend outward beyond the core on at least one end of the panel to define a recess between the skins. The recess between the skins may receive the flange. A bonding agent may be used to couple the flange to the inner walls of the panel.

Abstract: A composite member with a reinforced rampdown or taper has a composite noodle bonded to an end of a core to fill the taper.

Abstract: A bonded composite joint may include a base having a foot configured to couple to a member. The base may include a flange extending outward from the foot. The joint further may include a panel having a core positioned between opposing skins, where the skins have inner walls proximate the core and the skins extend outward beyond the core on at least one end of the panel to define a recess between the skins. The recess between the skins may receive the flange. A bonding agent may be used to couple the flange to the inner walls of the panel.

Abstract: A bonded composite joint may include a base having a foot configured to couple to a member. The base may include a flange extending outward from the foot. The joint further may include a panel having a core positioned between opposing skins, where the skins have inner walls proximate the core and the skins extend outward beyond the core on at least one end of the panel to define a recess between the skins. The recess between the skins may receive the flange. A bonding agent may be used to couple the flange to the inner walls of the panel.

Abstract: A joint is formed by joining two structures using a joint element. The joint element has a base and at least two legs extending from the base, the legs defining a slot having opposing sides and a bottom. The joint element is attached to the first structure. A second structure is positioned in the slot. An adhesive is disposed in the slot joining the second structure to the joint element. A cavity is formed between the bottom of the slot and the second structure. The cavity being substantially free of adhesive.

Abstract: A joint is formed by joining two structures using a joint element. The joint element has a base and at least two legs extending from the base, the legs defining a slot having opposing sides and a bottom. The joint element is attached to the first structure. A second structure is positioned in the slot. An adhesive is disposed in the slot joining the second structure to the joint element. A cavity is formed between the bottom of the slot and the second structure. The cavity being substantially free of adhesive.

Abstract: Embodiments of methods and apparatus for providing a double shear joint for bonding in structural applications are disclosed. In one embodiment, a bonded composite joint includes a base having a foot configured to couple to a member, the base including a flange extending outward from the foot. The joint further includes a panel having a core configured between opposing skins, the skins having inner walls proximate the core, the skins extending outward beyond the core on at least one end of the panel to define a recess between the skins, the recess configured to receive the flange. A bonding agent is used to couple the flange to the inner walls of the panel.

Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: A product including a first structure. A joint element is attached to the first structure. The joint element has a base and at least two legs extending from the base, the legs defining a slot having opposing sides and a bottom. A second structure is positioned in the slot. An adhesive is disposed in the slot joining the second structure to the joint element. A cavity is formed between the bottom of the slot and the second structure. The cavity being substantially free of adhesive.

Abstract: A composite member with a reinforced rampdown or taper has a composite noodle bonded to an end of a core to fill the taper.

Abstract: Composite sections for aircraft fuselages and other structures, and methods and systems for manufacturing such sections, are disclosed herein. A method for manufacturing a shell structure in accordance with one embodiment of the invention includes applying composite material to an interior mold surface of a tool to form a skin extending 360 degrees around an axis. The method can further include positioning a plurality of stiffeners on an inner surface of the skin. After the stiffeners have been positioned, a vacuum bag can be installed over the stiffeners and evacuated to press the stiffeners and the skin outwardly against the interior mold surface of the tool. Next, the skin/stiffener combination can be cocured to bond the stiffeners to the skin and harden the shell structure.

Abstract: A product including a first structure. A joint element is attached to the first structure. The joint element has a base and at least two legs extending from the base, the legs defining a slot having opposing sides and a bottom. A second structure is positioned in the slot. An adhesive is disposed in the slot joining the second structure to the joint element. A cavity is formed between the bottom of the slot and the second structure. The cavity being substantially free of adhesive.

Abstract: A method of joining a first structure to a second structure using a joint element. The joint element has a base and at least two legs extending from the base and the legs define a slot having opposing sides and a bottom. The method comprises attaching the joint element to the first structure and inserting the second structure into the slot. The method further includes injecting an adhesive into the slot. The method also includes ensuring a cavity is formed between the bottom of the slot and the second structure and the cavity is substantially free of adhesive.

Abstract: A composite member with a reinforced rampdown or taper has a composite noodle bonded to an end of a core to fill the taper.

Abstract: A method of joining a first structure to a second structure using a joint element. The joint element has a base and at least two legs extending from the base and the legs define a slot having opposing sides and a bottom. The method comprises attaching the joint element to the first structure and inserting the second structure into the slot. The method further includes injecting an adhesive into the slot. The method also includes ensuring a cavity is formed between the bottom of the slot and the second structure and the cavity is substantially free of adhesive.