Skin-stiffener transition assembly, method of manufacture and application of said skin-stiffener transition assembly

1. A skin-stiffener transition assembly with a skin and two fiber-reinforced fabric preforms for a flange and a composite gusset filler integrated between said skin and said two fiber-reinforced fabric preforms, said composite gusset filler being preformed to an essentially polygonal cross section, characterized in that the skin comprises two separate skin layers and the flange comprises a flange layer, each of said skin layers and said flange layer being provided with cut outs along one side, at least one of said cut outs being bent relative to at least one adjacent cut out, and said skin layers and the flange layer being attached to the composite gusset filler with at least one of their cut-outs to one side of the essentially polygonal cross section of the composite gusset filler and with at least one of their adjacent cut-outs to another side of the essentially polygonal cross section of the composite gusset filler.

2. The skin-stiffener transition assembly according to claim 1 , wherein the bent cut-outs are bent with an angle <90° relative to their respective plains of said skin layers or said flange layer.

3. The skin-stiffener transition assembly according to claim 1 , wherein the essentially polygonal cross section of the composite gusset filler is triangular or trapezoidal.

4. The skin-stiffener transition assembly according to claim 3 , wherein the composite gusset filler is cut with a trapezoidal cross section from a prepreg or pressed compound plate.

5. The skin-stiffener transition assembly according to claim 1 , wherein the composite gusset filler is rolled from tapes or tissues and subsequently shaped.

6. The skin-stiffener transition assembly according to claim 1 , wherein the depth of the cut outs are adapted to the dimensions of the cross section of the composite gusset filler.

7. The skin-stiffener transition assembly according to claim 1 , wherein the lengths b of the cut outs at a side of said skin layers and said flange layer are adapted for intersection of said skin layers and said flange layer.

8. The skin-stiffener transition assembly according to claim 1 , wherein the cuts are not rectangular to the side of said skin layers and said flange layer.

9. The skin-stiffener transition assembly according to claim 1 , wherein the cut outs have a depth allowing a fiber to pass at an angle of 45° straight from a corner at the side into the skin layers or said flange layer.

10. An aerospace component comprising one of a helicopter airframe, helicopter structural part, airplane door, an airplane frame and a non-aerospace applications with the skin-stiffener transition assembly according to claim 1 incorporated therein.

11. A method of manufacture of said skin-stiffener transition assembly according to claim 1 , comprising the steps of:

(a) providing a skin comprising skin layers and a flange comprising a flange layer;

(b) cutting along one side of each of said skin layers and said flange layer;

(c) bending open a part or all of the cut-outs along the one cut side of each of said skin layers and said flange layer;

(d) providing a semi-finished composite gusset filler; and

(e) attaching said cut outs along the cut sides to the composite gusset filler with the bent open cut-outs to at least one side of the essentially polygonal cross section of the composite gusset filler and with the remaining cut-outs to another side of the essentially polygonal cross section of the composite gusset filler.

12. The method according to claim 11 , characterized by providing the semi-finished composite gusset filler by ultrasonic cutting from a precompacted or pressed preform.

13. The method according to claim 11 , characterized by providing the semi-finished composite gusset filler by braiding and by subsequently pressing to a round, trapezoidal or triangular shape.

14. The method according to claim 11 , characterized by gluing said cut outs along the cut sides to the composite gusset filler.

15. A skin-stiffener transition assembly with a skin, a fiber-reinforced fabric flange, and a composite gusset filler integrated between the skin and the flange, the composite gusset filler having an essentially polygonal cross section, the skin comprising two separate skin layers and the flange comprising a flange layer, each of the skin layers and the flange layer being provided with cut outs along one side, at least one of the cut outs being bent relative to at least one adjacent cut out, and the skin layers and the flange layer being attached to the composite gusset filler with at least one of their cut-outs to one side of the essentially polygonal cross section of the composite gusset filler and with at least one of their adjacent cut-outs to another side of the essentially polygonal cross section of the composite gusset filler.

16. The skin-stiffener transition assembly according to claim 15 , wherein the bent cut-outs are bent with an angle <90° relative to their respective plains of the skin layers or the flange layer.

17. The skin-stiffener transition assembly according to claim 15 , wherein the depth of the cut outs are adapted to the dimensions of the cross section of the composite gusset filler.

18. The skin-stiffener transition assembly according to claim 15 , wherein the lengths of the cut outs at a side of the skin layers and the flange layer are adapted for intersection of the skin layers and the flange layer.

19. The skin-stiffener transition assembly according to claim 15 , wherein the cuts are not rectangular to the side of the skin layers and the flange layer.

20. The skin-stiffener transition assembly according to claim 15 , wherein the cut outs have a depth allowing a fiber to pass at an angle of 45° straight from a corner at the side into the skin layers or the flange layer.