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Abstract

Composite structures having a single continuous skin may be formed using automated fiber placement methods. These composite structures include frameless aircraft fuselage components offering an increased interior cabin width over conventional fuselage components. The composite structures may be constructed of multiple layers of fibers and other materials placed on a fiber placement tool that includes a mandrel body surrounded by a bladder or an integral bladder/caul sheet having expansion spaces created within the caul sheet section. Uncured composite structures may be created by placing fibers around the fiber placement tool in a plurality of discontinuous segments that are capable of moving or sliding in relation to each other so that the uncured composite structure is expandable from within. Fluid openings may be provided in the outer surface of the mandrel body for the application of vacuum and/or fluid pressure to secure the bladder to the mandrel body and to assist in the removal of the bladder from the mandrel body, respectively. Uncured composite structures may be sealed between the bladder and is clam shell molds. The uncured structures may be expanded against the inner surface of the molds by creating a vacuum between the bladder and molds.

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First Claim