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Aircraft fuselage structural components and methods of making sameAircraft fuselage structural components and methods of making same description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20090266936, Aircraft fuselage structural components and methods of making same. Brief Patent Description - Full Patent Description - Patent Application Claims
The present invention relates generally to structural components for aircraft fuselages and methods of making the same. In preferred embodiments, the present invention relates to structural panels for aircraft fuselages formed of transversal frame members and longitudinal stringers whereby stringer holes through the frame members are structurally reinforced. An aircraft fuselage is typically constructed as a series of longitudinally spaced circumferential frame members which define the general transversal (cross-sectional) fuselage shape, and a series of spaced stringer members running longitudinally with respect to the aircraft fuselage which contribute to the stiffness of the external skin. Together, the frames and stringers constitute a robust internal structure that provides support to the external fuselage skin. The fuselage skin covers various members of the internal support structure and is typically formed of a single piece or separate pieces of relatively thin material joined to the internal frames and stingers with skin splice straps. The frames and stringers are attached to the skin using different techniques. Usually, the stringers are installed to the skin in an earlier stage of the manufacturing cycle, using rivets and/or adhesives, to form stiffened skin panels. In a later stage, the stiffened skin panels are spliced and attached to the frames. The corresponding segments of the frames may be installed with each stiffened skin panel, forming framed stiffened skin panels. In a subsequent stage, the framed stiffened skin panels are assembled, and the skins and frames spliced to form a fuselage section. These stages are repeated until the fuselage is constructed. For those fuselage designs which have the frame members attached directly to the skin, there is a requirement that transverse openings need to be formed at appropriate locations to allow the stringers to pass therethrough. These openings, colloquially termed “mouse holes”, impose severe penalties on the strength of the frame members. As such, it is necessary to reinforce the frame members at the stringer openings in order to restore the frame member\'s original design strength. Various techniques can be found in the prior art regarding how to structurally strengthen stringer openings formed in fuselage frame members. For example, reinforcement members have been proposed to be riveted to the frame member in the vicinity of the stringer openings. However, this prior riveting technique has the disadvantage that the frame member must be drilled in order to accommodate the rivets, thereby sacrificing some of the frame member\'s structural integrity and strength. Alternatively, bonding a reinforcement piece has been proposed but this technique has the disadvantage that the reinforcement piece does not possess the same material strength compared to the frame member. Prior strengthening techniques are evident in U.S. Pat. Nos. 4,310,132; 6,648,273 and 7,134,629, the entire content of each being expressly incorporated hereinto by reference. It would be desirable if stringer openings could be reinforced without the need for riveting and/or bonding of the reinforcement piece to the frame member. It is towards fulfilling such need that the present invention is directed. Broadly the present invention is embodied in aircraft fuselage structures having reinforcement members in the vicinity of the stringer openings formed in frame members and rigidly lap joined to a surface region of the frame members by a friction stir weld region (e.g., a weld region formed by a friction stir welding process). According to some embodiments, an aircraft fuselage structural component is provided which comprises plural longitudinally spaced-apart frame members defining a transversal cross-section of an aircraft fuselage section, the frame members having a plurality of stringer holes therethrough, and plural longitudinally oriented stringers positioned within respective ones of the stringer holes of the frame member. The reinforcement members are most preferably formed of the same metal as the frame members to whom they are joined. In this regard, the reinforcement members are lap joined to corresponding surfaces of frame members in a vicinity of the stringer holes in such a way that the reinforcement members are joined rigidly to the corresponding surfaces of the frame members by a friction stir weld region. Certain embodiments of the invention will include reinforcement members which comprise a continuous or discontinuous structure. A fuselage skin may be attached to the frame members and/or stringers. According to some embodiments, the friction stir weld region is a continuous friction stir weld line. Alternatively or additionally, spot and/or discontinuous friction stir welds (with or without tool exit holes) may be employed. In some embodiments, the reinforcement members comprise an L-shaped flanged structure having one flange rigidly lap joined to a corresponding surface region of the frame member by the friction stir weld region. Alternatively or additionally, the reinforcement members comprise one of a curved plate rigidly lap joined to a corresponding surface region of the frame member by the friction stir weld region. The reinforcement members may be in the form of a reverse S-shaped structural member having a flange rigidly lap joined to a corresponding surface region of the frame member by the friction stir weld region. The flange of the S-shaped structural member may be rigidly lap joined to flange of the frame member. Alternatively, the flange of the S-shaped structural member may be rigidly lap joined to a center span of the frame member. The reinforcement members may alternatively or additionally comprise a reinforcement bar positioned laterally of a stringer opening and rigidly lap joined to a corresponding surface region of the frame member by the friction stir weld region. According to other embodiments of the invention, methods of making an aircraft fuselage structural component are provided which comprise providing plural longitudinally spaced-apart frame members defining a transversal cross-section of an aircraft fuselage section, the frame members having a plurality of stringer holes therethrough, positioning plural longitudinally oriented stringers within respective ones of the stringer holes of the frame members. Such stringer holes are structurally reinforced by lap joining reinforcement members to corresponding surfaces of frame members in the vicinity of the stringer holes. The reinforcement members are friction stir welded rigidly to the corresponding surfaces of the frame members to form a friction stir weld region therebetween. These and other aspects and advantages will become more apparent after careful consideration is given to the following detailed description of the preferred exemplary embodiments thereof. Reference will hereinafter be made to the accompanying drawings, wherein similar reference numerals throughout the various FIGURES denote similar structural elements, and wherein; Continue reading about Aircraft fuselage structural components and methods of making same... 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