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    • 专利摘要:
    invention patent summary: "composite ray fillers and methods of forming them". the present invention relates to an embodiment of a composite radius filler for a composite structure. the composite radius filler has two or more radius laminates. each ray laminate has a stacked composite layer laminate formed in a desired radius with a desired radial orientation of the stacked composite layers substantially combining with a radial orientation of adjacent stacked composite layers of a composite structure surrounding the two or more ray laminates. each radius laminate is preferably trimmed to have at least one lateral alignment adjacent to the others to form the composite radius filler having a shape substantially corresponding to a radius filler region of the composite structure.
    公开号:BR102013027708B1
    申请号:R102013027708
    申请日:2013-10-29
    公开日:2020-05-19
    发明作者:A Butler Geoffrey；S Nordman Paul
    申请人:Boeing Co；
    IPC主号:
    专利说明:

    Descriptive Report of the Invention Patent for COMPOUND RAY FILLINGS AND METHODS OF FORMING A COMPOUND RAY FILLING.
    BACKGROUND
    Description field
    [0001] The present invention generally relates to composite structures, and more specifically, to composite ray fillers for use in composite structures, such as in aircraft, and to methods for forming them.
    Description of the related technique
    [0002] Composite structures, such as structures composed of carbon fiber reinforced plastic (CFRP), are used in a wide variety of applications, including in the manufacture of aircraft, spaceship, spin aircraft, vessels, automobiles, trucks, and others vehicles and structures, due to their high strength and weight ratios, corrosion resistance and other favorable properties. In the construction of the aircraft, composite structures are used in increasing quantities to form the fuselage, wings, rear sections and other components.
    [0003] For example, aircraft wings may be formed of hardened composite panel structures that comprise composite cladding panels or reinforcements to which reinforcement hardeners or stringers can be attached or bonded to improve strength, toughness, warp resistance. and stability of composite cladding panels or reinforcements. Reinforcement hardeners or stringers attached or attached to composite cladding panels or reinforcements can be configured to carry multiple loads and can be supplied in a variety of different cross-sectional shapes, such as T hardeners, J hardeners, and I-beams To assist in the ability to carry wing load, a
    Petition 870200003334, of 1/8/2020, p. 5/54
    2/40 series of ribs can be connected to the stringers using tie rods. Figure 4A is an illustration of a perspective view of a known tie and monolithic rib assembly 68 for an aircraft wing 18 (see Figure 1). Figure 4A shows the monolithic ribs 70 with ties 72 that interface with the stringers 74 and cover panels 76. Figure 4B is an illustration of a perspective view of a known tie and the aerodynamic load rib assembly 78 for a aircraft wing 18 (see Figure 1). Figure 4B shows ribs 80 with ribs 82.
    [0004] Vacuum gaps or regions can be formed by the radius of each curved piece of reinforcement hardeners, such as T-hardeners, J-hardeners and I-beams, when they are attached or joined perpendicularly to composite coating panels or reinforcements. Such gaps or vacuum regions can typically be referred to as ray-filled regions or pasta-like regions. Such ray-fill regions or pasta-like regions in reinforcement hardeners may be prone to cracking because they can be forced three-dimensionally. Radius filling elements or strips made of composite material or adhesive / epoxy material and having a generally triangular cross section can be used to fill the radius filling regions or pasta-like regions in order to provide additional structural reinforcement to such regions.
    [0005] Known configurations of ray fillers or strips exist. For example, such known configurations of radius filler elements or strips may include radius filler elements or CFRP strips that are extruded and tie all zero degree layers with unidirectional fibers. However, each of the radius filler elements or CFRP strips with an extruded zero-grade layer can have thermal expansion through the
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    3/40 resin thickness and shrinkage that can lead to high residual stresses, that is, internal stresses created within a component during manufacture, such as residual thermal stress that can be created during thermal curing. In addition, the unidirectional fibers of such radius filler elements or CFRP strips with an extruded zero-grade layer may have low shrinkage force and may separate as a result of the high residual stresses that can be created during thermal curing at high temperatures, that is, as 176 ° C (350 degrees Fahrenheit) or greater, and the subsequent exposure to cold temperatures, that is, as less than - 53 ° C (- 65 (minus sixty-five) degrees Fahrenheit), which can, successively lead to stress cracking or fatigue in the radius filler elements or CFRP strips. To decrease the likelihood of such a stress or fatigue crack due to low retraction force and high retraction loads, the use of tie rods on the wing ribs may be required. However, the use of such risers can add weight to the aircraft due to the possible need for a riser at each location where a rib interacts with a stringer. The additional weight of the tie rods at each intersection between rib and stringer can reduce the aircraft's payload capacity and can increase fuel consumption and fuel costs. In addition, the sum of one tie at each intersection between rib and stringer can increase manufacturing complexity, cost and production time.
    [0006] In addition, known radius filler elements or laminated strips exist and have a generally triangular cross section and are constructed using a layered pyramid in a single direction. However, such known radius filler elements or laminated strips can minimize residual thermal stresses at just two points or peaks of the known radius filler or laminated pasta element, but not all three.
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    4/40 points or peaks of the known ray filler or rolled pasta element.
    [0007] Thus, there is a need in the art for improved composite radius fillings and methods of forming them that provide advantages over known elements, assemblies and methods.
    SUMMARY
    [0008] This need for improved composite beam fillings and methods of forming them is satisfied. As discussed in the detailed description below, the improved composite ray fill modalities and methods of forming them can provide significant advantages over the elements, assemblies and methods.
    [0009] In one embodiment of the description, a composite radius filler is provided for a composite structure. The composite radius filler comprises two or more radius laminates. Each radius laminate comprises a laminate of stacked composite layers formed in a desired radius with a desired radial orientation of the stacked composite layers substantially combining with a radial orientation of the adjacent stacked composite layers of a composite structure surrounding the two or more laminates of lightning. Each radius laminate is preferably trimmed to have at least one lateral alignment adjacent to the others to form a composite radius filler having a shape substantially corresponding to a radius fill region of the composite structure.
    [00010] In another embodiment of the description, an aircraft composite assembly is provided. The composite aircraft assembly comprises a composite structure with a radius-filled region. The composite aircraft assembly comprises
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    5/40 additionally a composite radius filler that fills the radius filler region. The composite radius filler comprises two or more radius laminates. Each ray laminate comprises a stacked composite layer laminate formed in a desired radius with a desired radial orientation of the stacked composite layers substantially combining with a radial orientation of adjacent stacked composite layers of the composite structure surrounding the two or more ray laminates. Each radius laminate is preferably trimmed to have at least one lateral alignment adjacent to the others to form the composite radius filler having a shape substantially corresponding to the radius filler region of the composite structure.
    [00011] In another embodiment of the description, a method of forming a composite radius filler is provided. The method comprises the steps of rolling a laminate of composite layers stacked one or more times around a forming tool with a desired radius to form a composite laminate arrangement of a desired thickness. The method further comprises the step of performing the composite laminate arrangement to remove voids. The method further comprises the step of aligning all seams of the composite laminate arrangement in one or more desired parts to be removed from the composite laminate arrangement. The method further comprises the step of removing one or more desired parts of the composite laminate arrangement in one or more cuts tangent to one or more surfaces of the forming tool. The method further comprises the step of removing two or more radius laminates from the composite laminate arrangement from the forming tool. The method further comprises the step of aligning two or more radius laminates together to form a composite radius filler provided with
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    6/40 a shape substantially corresponding to a radius-filling region of a composite structure. Each radius laminate is formed at a desired radius with a desired radial orientation of stacked composite layers substantially combining with a radial orientation of the adjacent stacked composite layers of the composite structure surrounding the composite ray fill. [00012] The characteristics, functions and advantages that have been discussed can be achieved independently in various modalities of the description or can be combined in still other modalities, more details of which can be seen with reference to the description and the following drawings.
    BRIEF DESCRIPTION OF THE DRAWINGS
    [00013] The description can be better understood with reference to the following detailed description taken in conjunction with the accompanying drawings that illustrate preferred and exemplary modalities, but which are not necessarily drawn on a ladder, where: [00014] Figure 1 is an illustration of a perspective view of an aircraft that can incorporate one or more composite assemblies provided with one or more composite structures with a composite radius fill modality of the description;
    [00015] Figure 2 is an illustration of a flow diagram of an aircraft production and service method;
    [00016] Figure 3 is an illustration of an aircraft block diagram;
    [00017] Figure 4A is an illustration of a perspective view of a known tie and the monolithic rib assembly for an aircraft wing;
    [00018] Figure 4B is an illustration of a perspective view of a known tie and the aerodynamic load rib assembly for an aircraft wing;
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    7/40
    [00019] Figure 5A is an illustration of a perspective view of a composite structure in the form of a T-hardener provided with a filled radius filler region with a composite radius filler embodiment of the description;
    [00020] Figure 5B is an illustration of a frontal, fragmented and enlarged sectional view of a composite assembly that incorporates the T hardener of Figure 5A provided with the composite radius filler;
    [00021] Figure 6A is an illustration of a schematic representation of a frontal sectional view of exemplary modalities of a forming tool and a laminate that can be used in one of the modalities of a method of forming a composite radius filler modality description;
    [00022] Figure 6B is an illustration of an enlarged front sectional view of an exemplary embodiment of a composite laminate arrangement that can be used in one of the embodiments of a method of forming a composite radius filler embodiment of the description;
    [00023] Figure 7A is an illustration of a schematic representation of a frontal sectional view of exemplary modalities of a forming tool and a laminate that can be used in each other of the modalities of a method of forming a radius filler modality description compound;
    [00024] Figure 7B is an illustration of an enlarged front sectional view of another exemplary embodiment of a composite laminate arrangement that can be used in one embodiment of a method of forming a composite radius filler embodiment of the description;
    [00025] Figure 8A is an illustration of an enlarged front sectional view of an exemplary embodiment of a
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    8/40 composite laminate with tangent cuts to the surfaces of the forming tool that can be used in one of the modalities of a method of forming a composite radius fill modality of the description;
    [00026] Figure 8B is an illustration of an enlarged front sectional view of the composite laminate arrangement of Figure 8A with parts removed leaving the radius laminates to form the composite radius fillers of the description;
    [00027] Figure 8C is an illustration of an enlarged front sectional view of one of the modal ray filler embodiments of the description;
    [00028] Figure 8D is an illustration of an enlarged front sectional view of another embodiment of a composite radius filler of the description;
    [00029] Figure 9 is an illustration of an exploded and enlarged front sectional view of another one of the modal ray filler modalities of the description; and,
    [00030] Figure 10 is an illustration of a flow diagram of an exemplary embodiment of a method of the description.
    DETAILED DESCRIPTION
    [00031] The modalities described now will be described more fully, hereinafter, with reference to the attached drawings, in which some, but not all of the modalities described are shown. In fact, several different modalities can be provided and should not be interpreted as limited to the modalities set out in the present. Preferably, these modalities are provided so that this description is meticulous and complete and will fully guide the scope of the description for those skilled in the art.
    [00032] Now, referring to the Figures, Figure 1 is an illustration
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    9/40 from a perspective view of an aircraft 10 that can incorporate one or more composite assemblies 26 with one or more composite structures 28 provided with a composite radius filler 100 (see Figure 5B), such as, for example, a composite radius filler 100a (see Figure 8C), a composite radius filler 100b (see Figure 8D), or a composite radius filler 100c (see Figure 9), formed by one or more modalities of a method 200 (see Figure 10) of the description. As shown in Figure 1, aircraft 10 comprises a fuselage 12, a nozzle 14, a cockpit 16, wings 18, one or more propulsion units 20, a vertical rear part 22, and horizontal rear parts 24. Very although the aircraft 10 shown in Figure 1 is generally representative of a commercial passenger aircraft with one or more composite assemblies 26 with one or more composite structures 28, the teachings of the described modalities can be applied to another passenger aircraft, cargo aircraft , military aircraft, gyroplane and other types of aircraft or air vehicles, as well as aerospace vehicles, satellites, launch vehicles into space, rockets and other aerospace vehicles, as well as boats and other vessels, trains, automobiles, trucks, buses or other suitable structures having one or more composite assemblies 26 with one or more composite structures 28 made with one or more modalities of method 200 (vid and Figure 10) of the description.
    [00033] Figure 2 is an illustration of a flow diagram of an aircraft production and service method 30. Figure 3 is an illustration of a block diagram of an aircraft 50. Referring to Figures 2 to 3 , the coating modalities can be described in the context of the service and manufacturing method of aircraft 30 as shown in Figure 2 and aircraft 50 as shown in
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    Figure 3. During pre-production, the example method 30 can include the specification and design 32 of the aircraft 50 and the acquisition of material 34. During production, component and subassembly manufacturing 36 and system 38 integration occur. aircraft 50. Consequently, aircraft 50 can pass certification and release 40 to be placed in service 42. While in service 42 by a customer, aircraft 50 can be staggered for routine maintenance and service 44 (which may also include modification, reconfiguration, renewal and other appropriate services).
    [00034] Each of the method 30 processes can be performed or performed by a system integrator, a third party and / or an operator (for example, a customer). For the purposes of this description, a system integrator may include, without limitation, any number of aircraft manufacturers and main system subcontractors; a third party may include, without limitation, any number of sellers, subcontractors and suppliers; and an operator can be an airline, leasing company, military entity, service organization and other suitable operators.
    [00035] As shown in Figure 3, the aircraft 50 produced by the exemplary method 30 may include an airplane frame 52 with a plurality of systems 54 and an interior 56. Examples of high-level systems 54 may include one or more of one propulsion system 58, an electrical system 60, a hydraulic system 62 and an environmental system 64. Any number of other systems can be included. Although an example of an aerospace industry is shown, the principles of the invention can be applied in other industries, such as the automotive industry.
    [00036] The methods and systems incorporated in the present can be used during any one or more of the stages of the service and production method 30. For example, the components
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    11/40 or subassemblies corresponding to component and subassembly manufacture 36 may be manufactured or manufactured in a similar manner to the components or subassemblies produced while the aircraft 50 is in service. Also, one or more device types, method methods or a combination of them, can be used during component and subassembly manufacturing 36 and system integration 38, for example, by substantially shipping the assembly or by reducing the cost of assembly. aircraft 50. Similarly, one or more modes of the apparatus, method modalities or a combination of them, can be used while aircraft 50 is in service, for example, and without limitation, for maintenance and service 44.
    [00037] In one embodiment of the description, a compound radius filler 100 (see Figures 5A-5B), that is, noodles, is provided to fill a radius filler region 116 (see Figures 5A5B), that is, region type of pasta, in a composite structure 28 (see Figure 5A). Figure 5A is an illustration of a perspective view of a composite structure 28 in the form of a T-hardener 90 provided with a radius filler region 116 filled with a compound radius filler 100 embodiment of the description. Figure 5B is an illustration of a fragmented and enlarged sectional front view of a composite assembly 26 incorporating the T-hardener 90 of Figure 5A which has the composite radius filler 100.
    [00038] As shown in Figure 5A, composite structure 28 in the form of T-hardener 90 comprises vertical reinforcements 92, horizontal flanges 96, and flange transitions for reinforcement 97 that radially surround the composite radius filler 100. As further shown in 5A, the flanges 96 of the T-hardener 90 can be joined to one or more base laminates 110 and / or
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    12/40 coating panels 114 on an interface 102, for example, an interface between coating and hardener. The one or more base laminates 110 and / or cladding panels 114 are preferably adjacent to and surrounding the composite radius filler 100.
    [00039] As shown in Figure 5B, in one embodiment, a composite assembly 26 comprises the T-hardener 90 with the vertical reinforcements 92, the horizontal flanges 96 and the radius filler region 116 filled with the composite radius filler 100. As further shown in Figure 5B, flanges 96 of the T-hardener 90 can be joined to one or more base laminates 110 and / or cladding panels 114. Composite assembly 26 further comprises beams 94 adjacent to the T-hardener 90.
    [00040] As additionally shown in Figure 5B, the composite radius filler 100 comprises two or more laminates of radius 142. Each laminate of radius 142 comprises a laminate 126 (see Figure 6A) of the stacked composite layers 134 (see Figures 5B, 6A ). Preferably, the laminate 126 of the stacked composite layers 134 has been performed to compress or consolidate the stacked composite layers 134 to remove voids, such as air or other gases, that may be trapped between the layers of the stacked composite layers 134. As additionally shown in Figure 5B, each laminate of radius 142 is preferably formed at a desired radius 98 with a desired radial orientation 99 of the stacked composite layers 134. The desired radial orientation 99 of the stacked composite layers 134 is preferably substantially compatible with a radial orientation 117 (see Figure 5B) of the adjacent stacked composite layers 118 (see Figure 5B) of the composite structure 28 (see Figure 5A), such as
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    13/40 T-hardener 90, surrounding the two or more laminates of radius 142. Furthermore, the desired radial orientation 99 of the stacked composite layers 134 is preferable and also substantially compatible with a radial orientation 112 (see Figure 5A) of the composite structure 28 such as the adjacent base laminates 110 and / or cladding panels 114 that surround the base of the two or more laminates of radius 142. The way in which the stacked composite layers 134 curve around the desired radius 98 of each laminate of radius 142 follows the same radial orientation 117 (see Figure 5B) of the stacked composite layers 118 (see Figure 5B) in the surrounding composite structure 28, as the T 90 hardener (see Figure 5B), so that the stacked composite layers 134 are as a continuation of the stacked composite layers 118.
    [00041] The stacked composite layers 134 can preferably be formed of a reinforcement material encircled and supported on a matrix material, such as, for example, a pre-impregnated material. The reinforcement material may comprise high strength fibers, such as glass or carbon fiber, graphite, aromatic polyamide fiber, glass fiber or another suitable reinforcement material. The matrix material can comprise various polymer or resin materials, such as epoxy, polyester, vinyl ester resins, polyetheretherketone polymer (PEEK), polyetheretherketone polymer (PEKK), bismaleimide or another suitable matrix material. As used herein, “pre-impregnated” means a braided canvas or fabric or cloth-like tape material, for example, fiberglass or carbon fibers, which have been impregnated with an uncured or partially cured resin, which is flexible or enough to be formed into a desired shape, then "cured", for example, by applying heat in an oven or an autoclave, to harden the resin forming a structure reinforced by strong and rigid fiber. The layers composed
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    14/40 stacked logs 134 may be in the form of a pre-impregnated unidirectional tape, a unidirectional fiber tape, a carbon fiber reinforced plastic (CFRP) tape or another suitable thin; a carbon fiber reinforced plastic (CFRP) canvas, a pre-impregnated canvas, a woven canvas including a woven carbon fiber canvas, or another suitable canvas; a combination of a ribbon or a canvas from them; or another suitable composite material. The composite radius filler 100 is preferably made of the same resin and fiber material used to form components in composite assembly 26 (see Figure 5B), such as composite structure 28 (see Figure 5A), beams 94 (see Figure 5B), base laminates 110 (see Figure 5B) and cover panels 114 (see Figure 5B).
    [00042] Each of the two or more laminates of radius 142 (see Figure 5B) are preferably obtained by removing them from an arrangement of composite laminate 130 (see Figure 8A) by means of cuts 140 (see Figure 8A) made tangent to one or more surfaces 141 (see Figure 8A) of a forming tool 120 (see Figure 8A) wound with the composite laminate arrangement 130 (see Figure 8A). Each laminate of radius 142 may preferably have a generally triangular cross section. Each laminate of radius 142 is preferably trimmed to have at least one side 144 (see Figure 8B) adjacent to the others to form the composite radius filler 100 (see Figure 5B) having a shape substantially corresponding to the radius filler region of the composite structure 28 (see Figure 5A). In particular, each laminate of radius 142 is preferably trimmed to have at least one side 144 (see Figure 8B) aligned adjacent to at least one side 144 (see Figure 8B) of another laminate of radius 142 in order to form a vertical joint 104 (see Figure 5B), and successively, to form a composite radius filler 100 (see Figure 5B). The composite ray filling
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    100 preferably has a shape 101 (see Figure 5B) or geometry substantially corresponding to the shape or geometry of the radius fill region 116 (see Figures 5A-5B) of the composite structure 28 (see Figure 5A). The composite radius filler 100 is formed in order to fill the volume and assume the shape and geometry of the radius filler region 116 to be filled. The shape 101 (see Figures 5B, 8C, 8D) of the composite radius filler 100 (see Figure 5B) can preferably comprise a substantially pyramid-shaped configuration 103 (see Figures 5B, 8C, 8D). The composite radius filler 100 may preferably have a generally triangular cross section.
    [00043] As shown in Figure 5B, the individual stacked composite layers 134 of the composite radius filler 100 preferably form corner points at three stress concentration points 106a, 106b, 106c of the composite radius filler 100. Preferably, the radial orientation desired 99 (see Figure 5B) of the stacked composite layers 134 is selected to be substantially compatible with the thermal expansion coefficient (CTE) of the composite ray filler 100 (see Figure 5B), and in particular, is selected to be substantially match the CTE at each of the three stress concentration points 106a, 106b, 106c (see Figure 5B) of the composite radius filler 100 to the CTE or the CTEs of the respective stacked composite layers 118 (see Figure 5B) of the composite structure 28 (see Figure 5A), such as the T-90 hardener that surrounds the composite radius filler 100, to minimize or reduce the crack of the composite radius filler 100 of the stresses residual thermal ions, especially that can occur during thermal curing of the composite ray filler 100 and the composite structure 28. Preferably, the composite ray filler 100 minimizes residual thermal stresses at the three concentration points
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    16/40 tensioning 106a, 106b, 106c (see Figures 5B) of the composite beam filler 100 during thermal curing of the composite beam filler 100 and the composite structure 28. CTE compatibility preferably minimizes or reduces the possibility of composite radius filler 100 crack with residual thermal stresses. The modal ray filler modalities 100 preferably move the high residual thermal stresses away from the three stress concentration points 106a, 106b, 106c of the compound ray filler 100, thereby minimizing cracking and cracking. In addition, the modal ray filler modalities 100 preferably increase a retraction load and accentuate a retraction force. As used herein, shrinkage load means a shear load and / or impulse force applied to a composite structure, such as a reinforcement hardener, in locations where the composite structure is attached or attached to another composite structure, such as a panel. of composite or reinforcement coating, such that the shear load and / or the thrust force can cause the reinforcement hardener to be delimited or separated from the fixed composite structure.
    [00044] In another embodiment of the description, a method 200 of forming a composite radius filler 100 is provided (see Figure 5B). Preferably, the composite radius filler 100 is used to fill a radius filler region 116 (see Figure 5B) in a composite structure 28 (see Figures 1, 5A). Figure 10 is an illustration of a flow diagram of an exemplary embodiment of method 200 of the description. As shown in Figure 10, method 200 comprises step 202 of rolling or positioning a laminate 126 (see Figure 6A) of stacked composite layers 134 (see Figure 6A) one or more times around a forming tool 120 (see Figure 6A) which has a desired radius 121 (r1) (see
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    Figure 6A) in order to form an arrangement of composite laminate 130 (see Figure 6B) of a desired thickness (ti) (see Figure 6B). An exemplary embodiment of the winding step 202 is shown in Figures 6A-6B. Another exemplary embodiment of the rolling step is shown in Figures 7A-7B. However, such exemplary modalities are not intended to be limited to the modalities set forth herein, and other rolling or positioning processes can also be used in method 200.
    [00045] Figure 6A is an illustration of a schematic representation of a frontal sectional view of exemplary modalities of a forming tool 120 and laminate 126, as in the form of laminate 126a, which can be used in one of method 200 modalities to form a composite fill radius 100 embodiment of the description. As shown in Figure 6A, forming tool 120 can be in the form of a cylindrical mandrel 122 which can be elongated. However, training tools 120 of other suitable formats and configurations can also be used. The forming tool 120 (see Figure 6A) can have a desired radius 121 (n) (see Figure 6A). Preferably, the desired radius length 121 (n) can be in the range of about 0.635 cm (0.25 inch) to about 2.54 cm (1.0 inch). However, other suitable lengths of the desired radius 121 (η) can also be used.
    [00046] As shown in Figure 6A, an outer surface 124 of forming tool 120 can be positioned on a first end 125 of laminate 126, as in the form of laminate 126a, provided with stacked composite layers 134. Laminate 126 can be positioned on a training platform 128 (see Figure 6A) or another suitable surface for the rolling step 202. In the mode shown in Figures 6A-6B, the
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    18/40 forming 120 is preferably rolled in the direction indicated by the direction arrow (d) (see Figure 6A), and the rolling step 202 may comprise continuously rolling laminate 126 of the stacked composite layers 134 several times around the forming tool 120 to form the composite laminate arrangement 130 (see Figure 6B) of the desired thickness (ti) (see Figure 6B). The step of rolling 202 or positioning of the composite laminate arrangement 130, as in the form of composite laminate arrangement 130a (see Figure 6B), on the forming tool 120 can be carried out by means of a manual process or by means of an automated process with a known positioning device or machine.
    [00047] Figure 6B is an illustration of an enlarged front sectional view of an exemplary embodiment of the composite laminate layout 130, as in the form of composite laminate layout 130a, which can be used in one of the embodiments of method 200 of forming a description composite ray filler mode 100. As shown in Figure 6B, laminate 126 of stacked composite layers 134 can be continuously wound several times around forming tool 120 starting at the first end 125 and ending at a second end 127. As shown in Figure 6B, an overlapping splice 131 can be formed between the first end 125 and the second end 127 to connect or secure the second end 127 to the first end 125 or to connect or secure the second end 127 to the composite laminate 130. Alternatively, another type of splice, gasket, connection or fastening means can be used to connect or secure the second end 127 to the composite laminate arrangement 130. As additionally shown in Figure 6B, the composite laminate arrangement 130 that is formed preferably has a desired thickness (ti) that can be measured
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    19/40 at a distance between the outer surface 124 of the forming tool 120 and an outer surface 132 of the composite laminate arrangement 130.
    [00048] Figure 7A is an illustration of a schematic representation of a frontal sectional view of exemplary modalities of training tool 120 and laminate 126, as in the form of laminate 126b, which can be used in one of the method 200 of form a composite radius filler embodiment 100 of the description. As shown in Figure 7A, forming tool 120 is in the form of a cylindrical mandrel 122 which can be elongated. However, training tools 120 of other suitable formats and configurations can also be used. The forming tool 120 (see Figure 7A) can have a desired radius 121 (r1) (see Figure 7A). Preferably, the desired radius length 121 (r1) can be in a range of about
    0.635 cm (0.25 inch) to about 2.54 cm (1.0 inch). However, other suitable lengths of the desired radius 121 (r1) can also be used.
    [00049] As shown in Figure 7A, an outer surface 124 of forming tool 120 can be positioned on a first end 133 of laminate 126, as in laminate 126b, provided with stacked composite layers 134. Laminate 126 can be positioned on a forming platform 128 (see Figure 7A) or another suitable surface for the rolling step 202. In the embodiment shown in Figures 7A-7B, the forming tool 120 is preferably rolled in the direction indicated by the direction arrow (d) (see Figure 7A), and the winding step 202 may comprise winding the laminate 126 of the stacked composite layers 134 once around the forming tool 120 and either making a top seam, or overlap seam or otherwise
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    20/40 splicing, joining or bonding laminate 126 of the stacked composite layers 134 together to form the composite laminate layout 130 (see Figure 7B), as in the form of composite laminate layout 130b (see Figure 7B), of a desired thickness (t2) (see Figure 7B). The step of rolling 202 or positioning the composite laminate arrangement 130, as in the form of composite laminate arrangement 130b, on the forming tool 120 can be conducted by means of a manual process or by means of an automated process with an apparatus or machine to position known.
    [00050] Figure 7B is an illustration of an enlarged front sectional view of another exemplary embodiment of the composite laminate layout 130, as in the form of composite laminate layout 130b, which can be used in one of the modalities of method 200 of forming a mode of the description composite ray filler 100. As shown in Figure 7B, the stacked composite layer laminate 126 is preferably wound once around the forming tool 120 starting at the first end 133 and ending at a second end 135. As shown in Figure 7B, a top splice 138 it can be formed between the first end 133 and the second end 135 to connect or secure the first end 133 to the second end 135 of the composite laminate arrangement 130. Alternatively, an overlap seam 131 (see Figure 6B) or another type of seam , joint, connection or fastening means can be used to connect or secure the first end 133 to the second end 135. As additionally shown in Figure 7B, the composite laminate arrangement 130 that is formed preferably has a desired thickness (t2) that can be measured at a distance between the outer surface 124 of the forming tool 120 and an outer surface 136 of the arrangement of l amine compound 130.
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    [00051] As shown in Figure 10, method 200 further comprises the step of performing the composite laminate 130 arrangement to remove voids. The performance step 204 comprises compressing or consolidating the composite laminate arrangement 130 in order to remove voids, such as those formed by air or other gases that can be trapped between the layers of the stacked composite layers 134. The performance preferably increases the density of the arrangement composite laminate 130. Performance step 204 can be achieved by means of processes known as vacuum bagging the composite laminate arrangement 130 in the forming tool 120 under sufficient heat and / or pressure, and / or exposing the composite laminate arrangement 130 to sufficient heat and / or pressure in an autoclave or other heating vessel and / or pressure vessel suitable for a sufficient length of time to effectively perform the composite laminate arrangement 130.
    [00052] Method 200 may further comprise, after performance step 204, repeating each step between rolling step 202 and performance step 204 one or more times as necessary to obtain the composite laminate arrangement 130 of the desired thickness.
    [00053] As shown in Figure 10, method 200 additionally comprises step 206 of aligning all seams or joints or connections, for example, overlap seam 131 (see Figure 6B) and / or top seam 138 (see Figure 7B ), or another suitable splice, joint or connection of the composite laminate arrangement 130 in one or more desired parts 139 (see Figure 8A) to be removed from the composite laminate arrangement 130 (see Figure 8A). The alignment step 206 may comprise aligning the seams, for example, overlap seam 131 (see Figure 6B) and / or seam
    Petition 870200003334, of 1/8/2020, p. 25/54
    Top 22/40 138 (see Figures 7B, 8A), of the composite laminate arrangement 130 (see Figure 8A) in one or more desired parts 139 (see Figure 8A) to be removed, as in one or more of a position of 12 o'clock 141b (see Figure 8A), a 3 o'clock position 141d (see Figure 8A), a 6 o'clock position 141a (see Figure 8A), and / or a 9 o'clock position 141c (see Figure 8A) in the composite laminate 130 at the interface between the forming tool 120 and the composite laminate arrangement 130.
    [00054] As shown in Figure 10, method 200 further comprises step 208 of removing one or more desired parts 139 (see Figure 8A) from the composite laminate arrangement 130 (see Figure 8A) in one or more cuts 140 (see Figure 8A) tangent to one or more surfaces 141 (see Figure 8A) of forming tool 120 (see Figure 8A). The removal step 208 may preferably comprise making cuts 140, such as four orthogonal cuts, for example, from corner 143a (see Figure 8A) to corner 143d (see Figure 8A), from corner 143d to corner 143b (see Figure 8A) , from corner 143b to corner 143c (see Figure 8A), and from corner 143c to corner 143a, in order to form a substantially square configuration 151 (see Figure 8A) around forming tool 120 (see Figure 8A). Figure 8B is an illustration of an enlarged front sectional view of an exemplary embodiment of the composite laminate arrangement 130, as cuts 140 tangent to surface 141 of forming tool 120 that can be used in one of the embodiments of method 200 of forming a embodiment of the composite radius filler 100 of the description.
    [00055] The one or more desired parts 139 (see Figure 8A) of the composite laminate arrangement 130 (see Figure 8A) can be removed in one or more cuts 140 (see Figure 8A) tangent to one or more surfaces 141 (see Figure 8A) of the training tool
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    23/40
    120 when cutting the composite laminate arrangement 130 with a known cutting device using a known cutting process, such as an ultrasonic cutting device and ultrasonic cutting process, a canvas cutting device and canvas cutting process, a cutting device laser cutting and laser cutting process or another suitable cutting device and cutting process.
    [00056] As shown in Figure 10, method 200 further comprises step 210 of removing from the forming tool 120 two or more laminates of radius 142 (see Figure 8B) from the composite laminate arrangement 130 (see Figure 8B). Figure 8B is an illustration of an enlarged front sectional view of the composite laminate arrangement 130 of Figure 8A with parts 139 (see Figure 8A) removed, leaving the radius laminates 142, as in the form of a first pair of radius laminates 142 comprising first laminate of radius 142a and second laminate of radius 142b, and as in the form of a second pair of laminates of radius 142 comprising first laminate of radius 142c and second laminate of radius 142d, for use in forming radius fillers compound 100 of the description. As shown in Figure 8B, the laminates of radius 142 each have a generally triangular cross section.
    [00057] A first composite radius filler 100 (see Figure 8C) can be formed from the first pair of radius laminates 142, as a first radius laminate 142a (see Figures 8B, 8C) and second radius laminate 142b (see Figures 8B, 8C). Circle 149a (see Figure 8B) shows the part of the first radius laminate 142a that can be removed from forming tool 120 by means of a tangential cut 150a (see Figure 8B). Circle 149b (see Figure 8B) shows the portion of the second radius laminate 142b that can be removed from forming tool 120 by means of a tangential cut 150b (see Figure 8B). A second composite radius fill 100
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    24/40 similar to the composite radius filler 100 shown in Figure 8C can be formed from the second set of radius laminates 142, like the first radius laminate 142c (see Figure 8B) and the second radius laminate 142d (see Figure 8B). The part of the first laminate of radius 142c (see Figure 8B) can be removed from the forming tool 120 by a tangential cut 150c (see Figure 8B), and the part of the second laminate of radius 142d (see Figure 8B) can be removed from the forming tool 120 by a tangential cut 150d (see Figure 8B). Radius laminates 142, such as the first radius laminate 142a, the second radius laminate 142b, the first radius laminate 142c and the second radius laminate 142d can be removed with the tangential cuts 150a, 150b, 150c, 150d, respectively , when cutting the radius laminates 142 of forming tool 120 with a known cutting device and known cutting process, such as an ultrasonic cutting device and ultrasonic cutting process, a canvas cutting device and canvas cutting process, a laser cutting device and laser cutting process or another suitable cutting and cutting process device.
    [00058] As shown in Figures 8A-8B, the first laminate of radius 142a comprises a first side 144a, a second side 146a orthogonal to the first side 144a, a third radial side 148a adjacent to the forming tool 120, and stacked composite layers 134 which comprise radially oriented stacked composite layers 147a (see Figure 8B). As shown in Figures 8A-8B, the second radius laminate 142b comprises a first side 144b, a second side 146b orthogonal to the first side 144b, a third radial side 148b adjacent to the forming tool 120, and stacked composite layers 134 comprising layers radially stacked composite 147b (see Figure 8B). As shown in Figure 8A, the first radius laminate
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    25/40
    142c comprises a first side 144c, a second side 146c orthogonal to the first side 144c, a third radial side 148c adjacent to the forming tool 120, and stacked composite layers 134 which comprise radially oriented stacked composite layers 147c (see Figure 8B). As shown in Figure 8A, the second laminate of radius 142d comprises a first side 144d, a second side 146d orthogonal to the first side 144d, a third radial side 148d adjacent to the forming tool 120, and stacked composite layers 134 that comprise stacked composite layers radially oriented 147d (see Figure 8B).
    [00059] As shown in Figure 10, method 200 further comprises step 212 of aligning two or more radius laminates 142 together to form a composite radius filler 100 that has a shape substantially corresponding to a radius filler region 116 ( see Figure 5A) of a composite structure 28 (see Figure 5A). As shown in Figure 5B, each laminate of radius 142 is preferably formed at a desired radius 98 with a desired radial orientation 99 of stacked composite layers 134 substantially compatible with a radial orientation 117 of stacked composite layers 118 adjacent the composite structure 28 surrounding the composite radius filler 100. In one embodiment, alignment step 212 may comprise aligning a first laminate of radius 142a (see Figure 8C) with a second laminate of radius 142b (see Figure 8C) to form composite radius filler 100 ( see Figure 8C), as in the form of a composite radius filler 100a, which has a shape 101 (see Figure 8C) which comprises a substantially pyramid shaped configuration 103 (see Figure 8C). In another embodiment, the alignment step 212 may comprise aligning a first laminate of radius 142a (see Figure 8D), a second laminate of radius 142b (see
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    26/40
    Figure 8D), and a third laminate of radius 152 (see Figure 8D) to form the composite radius filler 100 (see Figure 8D), as in the form of composite radius filler 100b, which has a shape 101 (see Figure 8D) comprising a substantially pyramid 103 configuration (see Figure 8D). As shown in Figure 8D, the third laminate of radius 152 is preferably positioned in a part 166 between the first laminate of radius 142a and the second laminate of radius 142b.
    [00060] Figure 8C is an illustration of an enlarged front sectional view of one of the modal ray filler modalities 100, as in the form of compound ray filler 100a, of the description. In this embodiment of the composite radius filler 100, as shown in Figure 8C, the two or more radius laminates 142 may comprise the first laminate of radius 142a aligned adjacent the second laminate of radius 142b to form a vertical joint 104, and successively for forming the composite radius filler 100. The composite radius filler 100 preferably has a shape 101 (see Figure 8C) substantially corresponding with a radius filler region 116 (see Figure 5A) of a composite structure 28 (see Figure 5A). Format 101 may preferably comprise a substantially pyramid 103 configuration (see Figure 8C). The composite radius filler 100, as in the form of composite radius filler 100a, may preferably have a generally triangular cross section.
    [00061] As shown in Figure 8C, the first side 144a of the first laminate of radius 142a can be aligned with the first side 144b of the second laminate of radius 142b to form the vertical joint 104. The second side 146a of the first laminate of radius 142a and the second side 146b of the second radius laminate 142b can be aligned in a substantially straight line to form the base of the
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    27/40 composite radius filler 100. The third radial side 148a of the first laminate of radius 142a is preferably positioned outwardly and is preferably adjacent to the composite structure 28 and corresponds to it (see Figure 5A), as the T 90 hardener ( see Figure 5B). The third radial side 148b of the second laminate of radius 142b is also preferably positioned outwardly and is also preferably adjacent to the composite structure 28 and corresponds to it (see Figure 5A), like the T-hardener 90 (see Figure 5B). As shown in Figure 8C, the third radial side 148a is preferably positioned opposite the third radial side 148b.
    [00062] Similar to the first radius laminate 142a and the second radius laminate 142b that can be combined to form the composite radius filler 100, as in the form of the composite radius filler 100a, the first radius laminate 142c (see Figure 8B ) and the second laminate of radius 142d (see Figure 8B) can also be combined to form a composite radius filler 100, as in the form of a composite radius filler 100a. The first radius laminate 142c (see Figure 8B) and the second radius laminate 142d (see Figure 8B) can be aligned adjacent to each other in a manner and configuration similar to the first radius laminate 142a and the second radius laminate 142b in Figure 8C in order to form another composite radius filler 100.
    [00063] Figure 8D is an illustration of an enlarged front sectional view of another embodiment of the composite radius filler 100, as in the form of compound radius filler 100b, of the description. In this embodiment, as shown in Figure 8D, a trilaminate composite radius filler comprises three laminates of radius 142. As shown in Figure 8D, the three laminates of radius 142 may comprise a first laminate of radius 142a, a second laminate of radius 142b ( or alternatively a first
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    28/40 mined with radius 142c (see Figure 8B) and a second laminate with radius 142d (see Figure 8B)), and a third laminate with radius 152 (see Figure 8D). As shown in Figure 8D, the third laminate of radius 152 comprises a first side 154, a second side 156 and a base 158. The third laminate of radius 152 is preferably of a shape and size sufficient to be able to fit between and adjacent the first ray laminate 142a and the second ray laminate 142b, respectively (or alternatively, to fit between and adjacent to the first ray laminate 142c (see Figure 8B) and the second ray laminate 142d (see Figure 8B), respectively ). As shown in Figure 8D, the third laminate of radius 152 may be in the form of a substantially pyramid-shaped configuration 105. The third laminate of radius 152 further comprises stacked composite layers 134 provided with a desired radial orientation 159 that is substantially compatible with a radial orientation of the adjacent base laminates 110 (see Figure 5A), cladding panels 114 (see Figure 5A), or a composite reinforcement 108 (see Figure 9).
    [00064] As shown in Figure 8D, the first laminate of radius 142a, the second laminate of radius 142b, and the third laminate of radius 152 are all aligned to form a composite radius filler 100, as in the form of composite radius filler 100b. As shown in Figure 8D, the first radius laminate 142a can be substantially aligned adjacent the second radius laminate 142b to form a vertical joint 104c. As additionally shown in Figure 8D, a portion 160a of the first radius laminate 142a can also be aligned adjacent the first side 154 of the third radius laminate 152 to form a joint 104a. As additionally shown in Figure 8D, a portion 160b of the second laminate of radius 142b can be aligned adjacent to its
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    29/40 on the side 156 of the third laminate of radius 152 to form a joint 104b. As additionally shown in Figure 8D, the third radius laminate 152 can preferably be positioned in an area 166 (see Figure 8D) between the first radius laminate 142a and the second radius laminate 142b, respectively (or alternatively between the first radius laminate). radius 142c (see Figure 8B) and the second laminate of radius 142d (see Figure 8B), respectively). Gasket 104a and gasket 104b can join vertical gasket 104c in area 166. The composite radius filler 100 preferably has a shape 101 (see Figure 8D) substantially corresponding to a radius filler region 116 (see Figure 5B) of the composite structure 28 (see Figure 5A). Format 101 may preferably comprise a substantially pyramid 103 configuration (see Figure 8D). The composite radius filler 100, as in the form of compound radius filler 100b, may preferably have a generally triangular cross section.
    [00065] As shown in Figure 10, method 200 may additionally comprise the optional step 214 of applying one or more adhesive layers 170 (see Figure 9) to the two or more laminates of radius 142 (see Figure 9) prior to curing of the filler composite radius 100 to facilitate load transfer into and out of each laminate of radius 142 after curing the composite radius filler 100. Figure 9 is an illustration of an exploded, front and enlarged sectional view of another one of embodiments of a compound ray filler 100, as in the form of compound ray filler 100c, of the description provided with one or more adhesive layers 170 applied to the compound ray filler 100, as in the form of compound ray filler 100c, to increase the connection or adhesion of the composite radius filler 100 to a composite structure 28 (see Figure 9) and / or a composite reinforcement 108 (see Figure 9).
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    [00066] To one or more adhesive layers 170 can preferably be applied before the composite radius filler 100 and the composite structure 28 are cured. The one or more adhesive layers 170 may comprise resin, epoxy adhesives, polyurethane adhesives, toughened acrylic adhesives, thermal adhesives such as polyamide (nylon) based adhesives, additional ionomers, or the like, or another suitable adhesive material.
    [00067] In addition, the adhesive layers 170 can be applied to the two or more laminates of radius 142 before curing the modalities of the composite radius filler 100a (see Figure 8C) and the composite radius filler 100b (see Figure 8D), as necessary. As for the composite radius filler 100a (see Figure 8C) and the composite radius filler 100b (see Figure 8D), preferably one or more adhesive layers 170 can be applied to the first side 144a (see Figures 8C-8D) of the first laminate of radius 142a (see Figures 8C-8D) and on the second side 144b (see Figures 8C8D) of the second laminate of radius 142b (see Figures 8C-8D) to facilitate the transfer of load into and out of each laminate of radius 142 , such as the first laminate of radius 142a and the second laminate of radius 142b, after curing.
    [00068] As shown in Figure 9, one or more adhesive layers 170 can be applied on the third radial side 148a of the first laminate of radius 142a, on the third radial side 148b of the second laminate of radius 142b, on the bottom of the base 158 of a third radius laminate 162 and on top of the third radius laminate 162. In addition, one or more adhesive layers 170 (not shown) can be applied between the first radius laminate 142a and the second radius laminate 142b, as needed, to facilitate the transfer of charge into and out of each radius laminate after curing.
    [00069] Figure 9 shows another type of filling
    Petition 870200003334, of 1/8/2020, p. 34/54
    31/40 trilaminate composite radius comprising three laminates of radius 142. As shown in Figure 9, the three laminates of radius 142 can comprise a first laminate of radius 142a, a second laminate of radius 142b (or alternatively a first radius laminate 142c (see Figure 8B) and a second laminate with radius 142d (see Figure 8B)), and a third laminate with radius 162 (see Figure 9). As shown in Figure 9, the third laminate of radius 162 comprises a base 158 and stacked composite layers 134 that have a desired radial orientation 159 that is preferably substantially compatible with a radial orientation 111 (see Figure 9) of the stacked composite layers 109 (see Figure 9) of a composite reinforcement 108 (see Figure 9). The third laminate of radius 162 is preferably of a shape and size sufficient to be able to fit between and adjacent the first laminate of radius 142a and the second laminate of radius 142b, respectively (or alternatively, to fit between and adjacent to the first laminate with radius 142c (see Figure 8B) and the second laminate with radius 142d (see Figure 8B), respectively). As shown in Figure 9, the third laminate of radius 162 can be positioned centrally between the first laminate of radius 142a and the second laminate of radius 142b, respectively, and along a central vertical geometry axis 164 that runs between the first laminate of radius 142a, the second laminate of radius 142b and the third laminate of radius 162. The composite radius filler 100, as in the form of composite radius filler 100c, preferably has a shape 101 (see Figure 9) substantially corresponding to a region of radius filling 116 (see Figure 5B) of the composite structure 28 (see Figure 9). Format 101 may preferably comprise a substantially pyramid 103 configuration (see Figure 9). The composite ray filler 100, as in the form of compound ray filler 100c, can preferably
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    32/40 have a generally triangular cross section.
    [00070] As shown in Figure 9, the first laminate of radius 142a, the second laminate of radius 142b, and the third laminate of radius 162 are all aligned to form a composite radius filler 100, as in the form of composite ray fill 100c. As shown in Figure 9, the first laminate of radius 142a can be substantially aligned adjacent to the second laminate of radius 142b. As additionally shown in Figure 9, the third radial side 148a of the first laminate of radius 142a is preferably positioned outwardly and is preferably adjacent to and corresponds to composite structure 28. Preferably, the stacked composite layers 134, as in the form of radially oriented stacked composite layers 147a, of the first radius laminate 142a are substantially compatible with a radial orientation 117 (see Figure 5B) of the adjacent stacked composite layers 118 (see Figure 9). vertical reinforcement 92 of the composite structure 28 (see Figure 9A) adjacent to the first laminate of radius 142a.
    [00071] The third radial side 148b of the second laminate of radius 142b is also preferably positioned outwardly and is also preferably adjacent to and corresponding to the surrounding composite structure 28. As shown in Figure 9, the third radial side 148a is preferably positioned opposite the third radial side 148b. Preferably, the stacked composite layers 134, as in the form of radially oriented stacked composite layers 147b, of the second radius laminate 142b are substantially compatible with a radial orientation 117 (see Figure 5B) of the adjacent stacked composite layers 118 (see Figure 9). vertical reinforcement 92 of the composite structure 28 (see Figure 9A) adjacent to the second laminate of radius 142b.
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    33/40
    [00072] After the uncured composite ray filler 100 is formed by the method 200 described herein, the uncured composite ray filler 100 can be cured prior to installation in the radius filler region 116 (see Figure 5A) of the structure composite 28. Alternatively, the uncured composite radius filler 100 can be installed in the radius filler region 116 (see Figure 5A) of composite structure 28 (see Figure 5A) and / or composite assembly 26 (see Figure 5B) and cured together with composite structure 28 and / or composite assembly 26. Curing may comprise a curing process known as an autoclave curing process, a vacuum bag curing process, a combination of autoclave curing processes and vacuum bag or other suitable curing process. Curing can take place at a high temperature and pressure as required by the material specifications to effectively cure the composite radius filler 100 and the composite structure 28 and / or the composite assembly 26. During curing, the composite material from the composite radius 100 hardens and, if installed in radius filler region 116 during curing, maintains the shape of radius filler region 116 in composite structure 28 and / or composite assembly 26.
    [00073] After curing the composite radius filler 100, if the cured composite radius filler 100 has been cured prior to installation in the radius filler region 116 (see Figure 5A) of the composite structure 28 and / or the composite assembly 26 , the cured radius filler 100 cured may be connected or linked in the radius filler region 116 of a composite structure 28 and / or composite assembly 26 cured or uncured by means of adhesive bonding, curing, secondary bonding or another process of known liaison or coalition. The bonding process can take place at a high temperature and pressure as required by the material specifications
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    34/40 to effectively connect or link the cured composite radius filler 100 in the radius filler region 116 of a cured or uncured composite structure 28 and / or composite assembly 26.
    [00074] The modalities of method 200 described herein form a composite radius filler 100 (see Figure 5A) that minimizes residual thermal stresses at three stress concentration points 106a, 106b, 106c (see Figure 5A) of the radius filler compound 100 during thermal curing of the composite radius filler 100. In addition, the modalities of method 200 described herein form a composite radius filler 100 (see Figure 5A) that enhances a shrinkage force, and the stacked composite layers 134 ( see Figure 5A) of the composite radius filler 100 redistributes a retraction load more evenly from a vertical reinforcement 92 (see Figure 5A) to a horizontal flange 96 (see Figure 5A) than the known composite radius fillers or strips.
    [00075] In another embodiment of the description, a composite assembly 26 of aircraft 10 is provided (see Figures 1, 5B). The composite assembly 26 of the aircraft 10 comprises a composite structure 28 (see Figures 1, 5A) provided with a radius filling region 116 (see Figure 5B). The composite structure 28 can comprise a T 90 hardener (see Figures 5A-5B). The T 90 hardener can comprise a transition between flange and reinforcement 97 (see Figure 5A) on a beam 94 (see Figure 5B) or a rib (see Figure 4B), or an interface 102 (see Figure 5A), as an interface between coating and hardener. The composite assembly 26 of the aircraft 10 further comprises a composite radius filler 100 (see Figure 5B) that fills the radius filler region 116. The composite radius filler 100 comprises two or more radius laminates 142 (see Figure 5B). Each laminate of radius 142 comprises a laminate 126 (see Figure 6A) of composite layers emi
    Petition 870200003334, of 1/8/2020, p. 38/54
    35/40 lines 134 (see Figure 5B) formed in a desired radius 98 (see Figure 5B) with a desired radial orientation 99 (see Figure 5B) of the stacked composite layers 134 substantially compatible with a radial orientation 117 (see Figure 5B) of stacked composite layers 118 adjacent (see Figure 5B) of the composite structure 28 (see Figure 5A), such as the T-hardener 90 (see Figure 5B), which surrounds the two or more laminates of radius 142 of the composite radius filler 100. Each laminate of radius 142 is preferably trimmed to have at least one side 144 (see Figure 8B) aligned adjacent to the others to form composite radius filler 100 having a shape 101 (Figure 5B) substantially corresponding to radius filler region 116 ( see Figure 5B) of the composite structure 28 (see Figure 5A).
    [00076] In one embodiment, as shown in Figure 8C, the two or more radius laminates 142 comprise a first laminate of radius 142a aligned adjacent to a second laminate of radius 142b to form the composite radius pad 100, as in the form of composite radius filler 100a, provided with a shape 101 which preferably comprises a substantially pyramid shaped configuration 103 and provided with a generally triangular cross section. In another embodiment, as shown in Figure 8D, the two or more radius laminates 142 comprise a first radius laminate 142a, a second radius laminate 142b and a third radius laminate 152 all aligned adjacent to each other to form the filling of composite radius 100, as in the form of composite radius filler 100b, provided with a shape 101 which preferably comprises a substantially pyramid shaped configuration 103 and provided with a generally triangular cross section. The third laminate of radius 152 is preferably positioned at a portion 166 between the first laminate of radius 142a
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    36/40 and the second laminate of radius 142b.
    [00077] As will be seen by those skilled in the art, incorporate the new composite radius filler 100 formed by the method 200 method described in composite structures 28 (see Figure 5A), for example, an aircraft wing structure 18 (see Figure 1), results in numerous substantial benefits. The described modalities of the composite ray filling 100 (see Figure 5A), 100a (see Figure 8C), 100b (see Figure 8D) and 100c (see Figure 9), and method 200 (see Figure 10) provide sequence compatibility of positioning or stacking the radial orientation of the stacked composite layers 134 of the radius laminates 142 with the radial orientation 117 (see Figure 5B) of the stacked composite layers 118 (see Figure 5B) of the surrounding composite structure 28 (see Figure 5A), and successively , the close compatibility of the mechanical properties, such as performance and stiffness, of the composite radius filler 100 with the mechanical properties, such as performance and stiffness, of the surrounding composite structure 28. By radially orienting the stacked composite layers 134 of the laminates of radius 142, the residual thermal stresses at three stress concentration points 106a, 106b and 106c (see Figure 5B) of the composite radius filler 100 can be minimized. Residual thermal stresses that can be created during the thermal curing process can preferably be minimized with the compound radius fillers 100 described herein due to the orthotropic nature of the individual stacked composite layers 134 and due to the higher thermal stress locations at three points or peaks of the composite ray filler 100 which are moved away from the three points or peaks and moved to the center of the composite ray filler 100. The compound ray fillers 100 described herein preferably have high thermal expansion through the thickness in the
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    37/40 z direction common to the top peak or stress concentration point 106c (see Figure 5A) of composite ray fillers, as well as high thermal expansion through thickness in the direction common to the bottom peaks or stress concentration points 106a , 106b (see Figure 5A).
    [00078] In addition, the described modalities of the composite ray filling 100 (see Figure 5A), 100a (see Figure 8C), 100b (see Figure 8D) and 100c (see Figure 9), and method 200 (see Figure 10 ) provide 100 composite radius fillers that minimize stress or fatigue cracking of 100 composite radius fillers that can occur at low temperatures, such as less than - 53 ° C (-65 (minus sixty-five) degrees Fahrenheit) and also allows larger radius 116 fill regions (see Figure 5A) to be formed. In addition, the described modalities of the composite ray fill 100 (see Figure 5A), 100a (see Figure 8C), 100b (see Figure 8D) and 100c (see Figure 9), and method 200 (see Figure 10) provide fillings of composite radius 100 that enhances the retraction force and redistributes the retraction load more evenly from the vertical reinforcements 92 (see Figure 5A) to the horizontal flanges 96 (see Figure 5A) of the composite structure 28, and that, plus a size of reduced acceptable failure at an intersection between stringer and rib can provide greater retraction compatibility. This can preferably eliminate the requirement for tie rods 72 (see Figure 4A) on the monolithic ribs 70 (see Figure 4A) in everything but locations where off-plane loads are transferred to aircraft wing 18 (see Figure 1), for example, flap rails or engine anchor anchoring locations.
    [00079] Furthermore, the described modalities of the composite ray filling 100 (see Figure 5A), 100a (see Figure 8C), 100b (see Figure 8D) and 100c (see Figure 9), and method 200 (see Figure 10) for
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    38/40 require the cutting of uncured parts of the composite laminate arrangement 130 (see Figure 8B) tangent to the forming tool 120 or to the mandrel 122 in four orthogonal cuts. This leaves four substantially pyramidal radius laminates 142 provided with a generally triangular cross section that can be aligned in pairs adjacent to each other to form a composite radius filler 100 of the same shape and geometry as the vacuum or volume of the fill region. radius 116 in the composite structure 28, such as a T-90 hardener (see Figure 5A) or a stringer 74 (see Figure 4A). The single composite radius filler 100 or noodles is formed by rolling laminate 126 of stacked composite layers 134 one or more times in a forming tool 120 such as a mandrel 122 (see Figure 6A) and then cutting off excess parts of the composite laminate arrangement 130 (see Figure 8A) of forming tool 120 until four laminates of radius 142 remain around forming tool 120. The four laminates of radius 142 can then be removed and combined in pairs to make two (2) composite radius fillers 100 of a bilaminated composite radius filler 100a (see Figure 8C) or a tri-laminated composite radius filler 100b (see Figure 8D) or another suitable composite radius filler. The described modalities of the composite ray filling 100 (see Figure 5A), 100a (see Figure 8C), 100b (see Figure 8D) and 100c (see Figure 9), and method 200 (see Figure 10) can provide radius fillings compound 100 endowed with increased structural properties to withstand stresses and shrinkage loads even greater than are achievable with known radius fillers and strips and can allow wings and other composite structures with higher performance to be manufactured.
    [00080] Many modifications and other description modalities
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    39/40 will occur to a person versed in the technique to which this description belongs with the benefit of the teachings presented in the previous descriptions and in the associated drawings. The modalities described herein are intended to be illustrative and are not intended to be limiting or exhaustive. Although specific terms are used at present, they are used in a generic and descriptive sense only and not for the purpose of limitation. According to a still further aspect of the present description, an aircraft composite assembly is provided which comprises: a composite structure provided with a radius-filled region; a composite ray fill that fills the ray fill region. The composite radius filler comprises: two or more radius laminates, each radius laminate comprising a stacked composite layer laminate formed in a desired radius with a desired radial orientation of the stacked composite layers substantially combining with a radial orientation of composite layers stacked adjacent the composite structure surrounding the two or more radius laminates, and each radius laminate is trimmed to have at least one lateral alignment adjacent to the others to form the composite radius filler having a shape substantially corresponding to the filling region of composite structure radius.
    [00081] In this way, the two or more radius laminates comprise a first radius laminate aligned adjacent to a second radius laminate to form the composite radius filler having a substantially pyramid shaped configuration.
    [00082] In this way, the two or more radius laminates comprise a first radius laminate, a second radius laminate and a third radius laminate all aligned adjacent to each other to form the composite radius pad provided with a configuration
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    40/40 substantially pyramid-shaped, the third ray laminate is positioned in a part between the first ray laminate and the second ray laminate.
    [00083] According to a still further aspect of the present description there is a method of forming a composite radius filler comprising the steps of: rolling a laminate of composite layers stacked one or more times around a forming tool provided with a desired radius to form a composite laminate arrangement of a desired thickness; performing the arrangement of composite laminate to remove voids; aligning all seams of the composite laminate arrangement in one or more desired parts to be removed from the composite laminate arrangement; removing one or more desired parts of the composite laminate arrangement in one or more cuts tangent to one or more surfaces of the forming tool; removing two or more radius laminates from the composite laminate arrangement from the forming tool; and, aligning the two or more radius laminates together to form a composite radius filler having a shape substantially corresponding to a radius fill region of a composite structure, each radius laminate is formed in a desired radius with a radial orientation stacked composite layers substantially combining with a radial orientation of the adjacent stacked composite layers of the composite structure surrounding the composite radius filler.
    [00084] In this way, the step of aligning the two or more radius laminates comprises aligning a first radius laminate with a second radius laminate adjacent to each other to form the composite radius filler provided with a substantially pyramid shape configuration .
    权利要求:
    Claims (13)
    [1]
    1. Composite radius fill (100) to fill a radius fill region (116) in a composite structure (28) characterized by the fact that it comprises:
    two or more radius laminates (142), each radius laminate comprising a stacked composite laminate (126) (134) formed to curve around a desired radius (98) with a desired radial orientation (99) of the composite layers stacked (134) configured to substantially match a radial orientation (117) of adjacent stacked composite layers (118) of the composite structure (28) surrounding the two or more radius laminates (142), and each radius laminate (142) trimmed to have at least one side (144) alignment adjacent to the others to form a vertical joint and, in turn, to form a composite radius filler (100) having a shape (101) configured to substantially match the filler region of radius (116) of the composite structure (28).
    [2]
    2. Composite radius filler (100) according to claim 1, characterized in that the two or more radius laminates (142) comprise a first radius laminate (142a) aligned adjacent to a second radius laminate ( 142b) to form the composite radius filler (100) having a substantially pyramid-shaped configuration (103).
    [3]
    3. Composite radius filler (100) according to claim 1, characterized in that the two or more radius laminates (142) comprise a first radius laminate (142a), a second radius laminate (142b) and a third radius laminate (152) all aligned adjacent to each other to form the composite radius filler (100) having a substantially pyramid shaped configuration, the third radius laminate (152) is po
    Petition 870200003334, of 1/8/2020, p. 45/54
    2/4 positioned in a part between the first radius laminate (142a) and the second radius laminate (142b)).
    [4]
    4. Composite radius fill (100) according to claim 1, characterized in that the desired radial orientation of the stacked composite layers (134) of each radius laminate (142) is selected to substantially match the expansion coefficient thermal strength at three points of stress concentration (106a-c) of the composite radius filler (100) with that of the adjacent stacked composite layers (118) of the composite structure (28) surrounding the compound radius filler (100) to minimize cracks in the composite radius filler (100) of residual thermal stresses.
    [5]
    5. Method (200) of forming a composite radius filler (100) characterized by the fact that it comprises the steps of:
    Wrapping (202) a laminate of stacked composite layers (134) one or more times around a forming tool (120) having a desired radius to form a composite laminate arrangement (130) of a desired thickness;
    performing (204) the arrangement of composite laminate (130) to remove voids;
    aligning (206) all seams of the composite laminate arrangement (130) in one or more desired parts to be removed from the composite laminate arrangement (130);
    removing (208) one or more desired parts (139) from the composite laminate arrangement (130) in one or more cuts (140) tangent to one or more surfaces (141) of the forming tool (120);
    removing (210) from the forming tool (120) two or more radius laminates (142) from the composite laminate arrangement (130); and
    Petition 870200003334, of 1/8/2020, p. 46/54
    3/4 align (212) the two or more radius laminates (142) together to form a composite radius filler (100) having a shape substantially corresponding to a radius filler region (116) of a composite structure (28) , each radius laminate (142) formed in a desired radius with a desired radial orientation of stacked composite layers (134) substantially combining with a radial orientation of the adjacent stacked composite layers (118) of the composite structure (28) that surrounds the filling of compound radius (100).
    [6]
    6. Method according to claim 5, characterized in that it further comprises applying one or more adhesive layers (170) to the two or more radius laminates (142) before curing the composite radius filler in order to facilitate the charge transfer in and out of each radius laminate (142) after curing the composite radius filler (100).
    [7]
    Method according to claim 5 or 6, characterized in that the step of rolling (202) comprises continuously rolling the laminate of stacked composite layers (134) several times around the forming tool (120) to form the composite laminate arrangement (130) of the desired thickness.
    [8]
    Method according to claim 5 or 6, characterized in that the step of rolling (202) comprises rolling the laminate of stacked composite layers (134) once around the forming tool (120) and or making top seam or seam by overexposing the stacked composite layer laminate (134) to form the composite laminate arrangement (130) of the desired thickness.
    [9]
    9. Method according to any one of claims 5 to 8, characterized by the fact that it still comprises after the performance step (204), repeating each one of the step of
    Petition 870200003334, of 1/8/2020, p. 47/54
    4/4 winding (202) and the performance step (204) one or more additional times to obtain the composite laminate arrangement (130) of the desired thickness.
    [10]
    Method according to any one of claims 5 to 9, characterized in that the step of aligning (206) all seams comprises aligning the seams of the composite laminate arrangement (130) in one or more of a position of 12 o'clock, a 3 o'clock position, a 6 o'clock position and a 9 o'clock position in the composite laminate arrangement (130).
    [11]
    Method according to any one of claims 5 to 10, characterized in that the step of removing (208) one or more desired parts comprises making four orthogonal cuts to form a substantially square configuration around the forming tool (120).
    [12]
    Method according to any one of claims 5 to 11, characterized in that the step of aligning (212) the two or more radius laminates (142) comprises aligning a first radius laminate (142a), a second radius laminate (142b) and a third radius laminate (152) adjacent to each other to form the composite radius filler (100) having a substantially pyramid shape, the third radius laminate (152) positioned in a part between the first spoke laminate (142a) and the second spoke laminate (142b).
    [13]
    13. Method according to any of claims 5 to 12, characterized in that the step of aligning the two or more radius laminates (142) comprises forming the composite radius filler (100) to minimize residual thermal stresses at three stress concentration points (106a-c) of the composite ray filler (100) during the thermal cure of the composite ray filler (100).
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    同族专利:
    公开号 | 公开日
    CA2829519C|2016-03-22|
    EP2727711A1|2014-05-07|
    AU2013234415A1|2014-05-15|
    US20150367619A1|2015-12-24|
    CA2829519A1|2014-05-01|
    US9370921B2|2016-06-21|
    EP2727711B1|2019-03-13|
    RU2013145432A|2015-04-20|
    CN103802337B|2018-02-02|
    RU2636494C2|2017-11-23|
    KR20140055993A|2014-05-09|
    JP2016028849A|2016-03-03|
    KR102030192B1|2019-10-08|
    ES2730732T3|2019-11-12|
    BR102013027708A2|2014-10-21|
    TR201907271T4|2019-06-21|
    CN103802337A|2014-05-21|
    JP6360672B2|2018-07-18|
    AU2013234415B2|2016-10-27|
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    法律状态:
    2014-10-21| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|
    2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |
    2019-10-15| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|
    2020-03-24| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-05-19| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 29/10/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/666,959|US9370921B2|2012-11-01|2012-11-01|Composite radius fillers and methods of forming the same|
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