Multi-functional aircraft structures

Abstract

A method for manufacturing a composite structure. A filler material with a barrier material for a channel in the filler material is formed. A composite material and the filler material with the barrier material are laid up onto a tool in a shape of the composite structure. The composite material and the filler material in the shape of the composite structure are cured.

1 . A method for manufacturing a composite structure, the method comprising:
 forming a filler material with a barrier material for a channel in the filler material;   laying up a composite material and the filler material with the barrier material onto a tool in a shape of the composite structure; and   curing the composite material and the filler material in the shape of the composite structure.   
     
     
         2 . The method of  claim 1 , wherein the forming step comprises:
 forming the filler material with the barrier material for the channel in a foam with a mandrel in the channel.   
     
     
         3 . The method of  claim 2  further comprising:
 removing the mandrel from the filler material to form the composite structure, wherein the barrier material forms a barrier for a channel in the composite structure. 
 
     
     
         4 . The method of  claim 1 , wherein the filler material is a foam, and wherein the laying up step comprises:
 laying up the composite material onto an inside mold line; and   placing the foam with the barrier material and a mandrel onto the composite material.   
     
     
         5 . The method of  claim 4 , wherein the laying up step further comprises:
 placing a skin ply over the foam and the composite material.   
     
     
         6 . The method of  claim 1 , wherein the filler material is a foam and wherein the laying up step comprises:
 placing the foam onto a skin ply; and   placing the composite material over the foam.   
     
     
         7 . The method of  claim 6 , wherein the laying up step is performed using an outside mold line. 
     
     
         8 . The method of  claim 1 , wherein the step of forming the filler material with the barrier material for the channel in the filler material comprises:
 forming the filler material with the barrier material for the channel in the filler material and for a number of channels in addition to the channel in the filler material.   
     
     
         9 . The method of  claim 1 , wherein the barrier material and the channel form a waveguide. 
     
     
         10 . The method of  claim 1 , wherein the channel includes at least one of a number of fiber optic cables, a number of power lines, a number of wires, and a number of data lines. 
     
     
         11 . The method of  claim 1 , wherein the barrier material and the channel are configured to receive a liquid, air, or a gas. 
     
     
         12 . The method of  claim 1 , wherein the barrier material is selected from a group consisting of a metal, copper, aluminum, titanium, a plastic, and polyvinyl chloride. 
     
     
         13 . The method of  claim 1 , wherein the filler material is selected from a group consisting of a foam, fiberglass, a honeycomb structure, a vibration-reduction material, an insulation material, and wood. 
     
     
         14 . The method of  claim 1 , wherein the composite structure is selected from a group consisting of a stringer, a frame, a floor panel, a cryogenic tank, a dry inter-stage structure, a spar, and a rib. 
     
     
         15 . The method of  claim 1 , wherein the channel and the barrier material are part of a system selected from a group consisting of an air duct, a fire suppression system, and a waveguide. 
     
     
         16 . The method of  claim 1 , wherein the composite structure is for a vehicle selected from a group consisting of an aircraft and a spacecraft. 
     
     
         17 - 31 . (canceled) 
     
     
         32 . The method of  claim 1 , wherein forming the filler material with the barrier material further comprises:
 forming the filler material to be disposed within and abutting all first inner walls of the composite structure.   
     
     
         33 . The method of  claim 32 , wherein the barrier material comprises a first barrier material, and wherein forming the filler material with the barrier material further comprises:
 securing the first barrier material to second inner walls of the filler material, the second inner walls being further within the composite structure relative to the first inner walls, and wherein third inner walls of the first barrier material define a first channel inside the composite structure.   
     
     
         34 . The method of  claim 33  further comprising:
 securing a second barrier material to fourth inner walls of the filler material, the fourth inner walls being further within the composite structure relative to the first inner walls, and fifth inner walls of the second barrier material defining a second channel inside the composite structure. 
 
     
     
         35 . The method of  claim 32 , wherein the barrier material comprises a first foam connected to a second foam.