US 11,981,426 B2
Composite spars with integrated sacrificial surfaces
Eric Sean Kamila, Edmonds, WA (US); Joseph Lee Sweetin, III, Leavenworth, WA (US); Josephine LaCoe, Seattle, WA (US); Chilip Chan, Seattle, WA (US); Clifford D. Borowicz, Mukilteo, WA (US); Roozbeh Chavoshian, Kenmore, WA (US); and Ian Edward Schroeder, Seattle, WA (US)
Assigned to The Boeing Company, Chicago, IL (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Oct. 26, 2021, as Appl. No. 17/510,378.
Claims priority of provisional application 63/134,071, filed on Jan. 5, 2021.
Prior Publication US 2022/0212777 A1, Jul. 7, 2022
Int. Cl. B64C 3/18 (2006.01); B64C 3/20 (2006.01); B64C 3/26 (2006.01); B64F 5/10 (2017.01)
CPC B64C 3/185 (2013.01) [B64C 3/20 (2013.01); B64C 3/26 (2013.01); B64F 5/10 (2017.01)] 20 Claims
OG exemplary drawing
 
1. A method of fabricating a composite assembly, the method comprising:
assembling a first composite layup that defines a web portion and flange portions for a composite spar of the composite assembly;
assembling a second composite layup onto at least one of the flange portions to define a sacrificial member for the composite assembly;
generating a tapered edge in the second composite layup;
aligning the tapered edge to a bend in the first composite layup between the web portion and the at least one of the flange portions such that a thickness of the second composite layup decreases towards the bend;
co-curing the first composite layup and the second composite layup to harden the composite assembly; and
machining an outer surface of the sacrificial member into conformance with an inner surface of at least one skin panel for an aircraft structure to form a contact surface for the at least one skin panel.