RAY FILLING LAMINATED COMPOSITE, AND, METHOD FOR FORMING A RAY FILLING LAMINATED COMPOSITE

专利摘要:
ray-fill laminate composite, and, method for forming a ray-fill laminate composite to ray-fill laminate composite for a composite structure has a stacked fold set having a plurality of cut laminated ray-fill fold stacks at a desired width and having a desired bend orientation. the laminated ray-filling composite also has a geometrically shaped filling element positioned in a desired location on a first portion of the stacked fold assembly. the geometrically shaped filler element deforms a second portion of the stacked fold set, stacked on the geometrically shaped filler element, so that the laminated radius filler folds of the second portion of the stacked fold set change direction and have a component direction including a horizontal direction and a vertical direction. the ray-fill laminate composite having a shape substantially corresponding to a ray-fill region of the composite structure.
公开号:BR102014021244B1
申请号:R102014021244-2
申请日:2014-08-27
公开日:2020-08-04
发明作者:Kirk B. Kajita；Douglas A. Frisch
申请人:The Boeing Company；
IPC主号:

专利说明:

FUNDAMENTALS 1) Description field
[0001] The description generally refers to composite structures and methods, and more specifically, to composite, beam radius fills for composite structures, such as aircraft structures, and methods of forming them. 2) Description of the Related Art
[0002] Composite structures, such as structures made of carbon fiber-reinforced plastic materials (CFRP), can be used in a wide variety of applications, including in the manufacture of aircraft, space vehicles, helicopters, boats, automobiles, trucks, and other vehicles and structures, due to their high strength to weight ratios, corrosion resistance and other favorable properties. In particular, in aircraft construction, composite structures can be used to form sections of tail, wings, fuselage and other components.
[0003] When composite structural elements are joined together, such as stiffening reinforcement or stringers joined to composite cladding panels, interstices or void regions, typically referred to as "radius fill regions" or "noodle regions" , may be present along connecting lines between the composite structural elements. Radius fillers or "noodles" made of composite material or adhesive / epoxy material and having a generally triangular cross section can be used to fill the radius fill regions or noodle regions, in order to provide additional structural reinforcement for such regions.
[0004] The ray-fill or noodle element used to fill the ray-fill region or noodle region can be in the form of a ray-fill laminate composite. Such known laminated composite ray fillers can be made of laminates formed from stacked composite folds. However, during fabrication curing and thermal cycling stages of such well-known composite, radius fillers, laminates, as used in composite structures including reinforcement stiffeners or stringers, delamination or bend separation can occur in composite, laminated radius fills. . Generally, such delamination occurs in an upper third of the area near the tip of the ray-filled laminate composite and can occur more frequently in larger, laminated, composite ray-fill. Such delamination is typically caused by a difference in the coefficient of thermal expansion (CTE) between the folds adjacent to the ray-fill laminate composite, i.e., envelope folds, and the ray-fill laminate composite.
[0005] The known solutions that address such delamination of the ray-fill composite laminate exist. For example, one of such a known solution involves showing that the delamination of the ray-filled laminate composite is not harmful. However, such a known solution can add risk, since it can be difficult to show that delamination will not grow to a harmful size under environmental and loading conditions for the life of a composite structure.
[0006] Thus, it is desirable to be able to solve the problem of delamination of laminated, composite ray fillers used in composite structures, such as reinforcement stiffeners and stringers. Consequently, there is a need in the art for improved composite, laminated ray fillings, and methods of forming them, which provide advantages over known elements, assemblies and methods. SUMMARY
[0007] This need for improved composite, laminated ray fillings and methods of forming them is satisfied. As discussed in the detailed description given below, modalities of the improved composite, laminated ray fillings, and methods of forming them, can provide significant advantages over the known elements, assemblies and methods.
[0008] In one embodiment of the description, a ray-filled laminated composite is provided for a composite structure. The ray-filled laminate composite comprises a stacked fold set. The stacked fold set comprises a plurality of stacks of laminated radius fill folds cut to a desired width and having a desired fold orientation.
[0009] The ray-filled laminate composite additionally comprises a geometrically shaped filling element, positioned in a desired location on a first portion of the stacked fold set. The geometrically shaped filler element deforms a second portion of the stacked fold assembly, stacked on top of the geometrically shaped filler element, so that the laminated radius filler folds of the second portion of the stacked fold set change direction and have a component of direction comprising a horizontal direction and a vertical direction. The ray-fill laminate composite has a shape substantially corresponding to a ray-fill region of the composite structure.
[00010] In another embodiment of the description, a composite aircraft set is provided. The composite aircraft assembly comprises a composite structure. The composite structure comprises a radius fill region and a plurality of envelope bends adjacent the radius fill region.
[00011] The aircraft composite assembly additionally comprises a laminated ray-fill composite having a shape substantially corresponding to the ray-fill region and fill-in the ray-fill region. The ray-filled laminate composite comprises a stacked fold set. The stacked fold set comprises a plurality of stacks of laminated radius fill folds cut to a desired width and having a desired fold orientation.
[00012] The ray-filled laminate composite additionally comprises a geometrically shaped filling element, positioned in a desired location on a first portion of the stacked fold assembly. The geometrically shaped filler element deforms a second portion of the stacked fold assembly, stacked on the geometrically shaped filler element, so that the laminated radius filler folds of the second portion of the stacked fold set change direction and have a component of direction comprising a horizontal direction and a vertical direction.
[00013] In another embodiment of the description, a method of forming a ray-filled laminated composite for a composite structure is provided. The method comprises the step of assembling a plurality of stacks of laminated radius fill folds cut to a desired width and having a desired fold orientation to form a stacked fold set. The method further comprises the step of laying a first portion of the folding set stacked on a forming apparatus. The method further comprises the step of positioning a geometrically shaped filling element in a desired location on the first portion of the stacked fold set.
[00014] The method further comprises the step of laying a second portion of the stacked fold set on the geometrically shaped filling element and the first portion to form a ray-filled laminated composite. The geometrically shaped filling element deforms the second portion, so that the rolled radius fill folds of the second portion change direction and have a direction component comprising a horizontal direction and a vertical direction. The method further comprises the step of assembling the ray-filled laminate composite in a radius-filling region of a composite structure.
[00015] The characteristics, functions, and advantages that have been discussed can be obtained independently in the various modalities of the description or can be combined in still other modalities, other details of which can be seen with reference to the following description and drawings.
[00016] In addition, the description comprises modalities according to the following clauses: Clause 1: A composite aircraft assembly comprising: a composite structure comprising a radius fill region and a plurality of enclosure folds adjacent to the radius fill region ; and, a ray-fill laminate composite having a shape substantially corresponding to the ray-fill region and ray-fill region, the ray-fill laminate composite comprising: fold orientation; and, a geometrically shaped filling element, positioned in a desired location on a first portion of the stacked fold set, the geometrically shaped filling element deforming a second portion of the stacked fold set, stacked on the geometrically shaped fill element, so that the laminated radius fill folds of the second portion of the stacked fold set change direction and have a direction component comprising a horizontal direction and a vertical direction. Clause 2: The composite aircraft assembly according to clause 1, wherein the ray-filled laminated composite additionally comprises a tip element positioned on an upper portion of the stacked fold assembly, the tip element comprising a plurality of fibers unidirectional fiber tape, unidirectional pre-impregnated tape, unidirectional composite tow, split unidirectional tape, carbon fiber reinforced plastic (CFRP) tape, carbon fiber reinforced plastic (CFRP) ), a prepreg fabric, a woven cloth including a woven carbon fiber cloth, chopped fiber, or a combination thereof. Clause 3: The aircraft composite assembly according to clause 1, wherein the ray-filled laminated composite additionally comprises one or more additional geometrically shaped filling elements, each positioned in a desired location on one or more additional portions of the stacked fold set, and each of the one or more additional geometrically shaped filling elements, further deforming one or more respective additional portions of the stacked fold set, stacked on the respective one or more geometrically shaped filling elements. Clause 4: The composite aircraft assembly according to clause 1, in which the geometrically shaped filling element comprises a plurality of unidirectional fibers, a unidirectional fiber tape, a pre-impregnated unidirectional tape, a unidirectional composite tow, a unidirectional split tape, a carbon fiber reinforced plastic (CFRP) tape, a carbon fiber reinforced plastic (CFRP) fabric, a prepreg fabric, a woven cloth including a woven carbon fiber cloth, fiber sting, or a combination thereof. Clause 5: The composite aircraft assembly according to clause 1, in which the geometrically shaped filling element has a geometric shape comprising one of a triangle shape, a triangle shape with curved vertices, an arrowhead shape, a triangle shape with removed vertices, a triangle shape with one or more curved sides, a radius fill shape, and a semicircle shape. Clause 6: The composite aircraft assembly according to clause 1, in which the change of direction of the rolled radius fill folds of the second portion minimizes a difference in the thermal expansion coefficient (CTE) and interlaminar tensile stress between the composite ray-fill laminate and the plurality of wrapping folds adjacent to the ray-fill laminate composite, resulting in the elimination of delamination or reduced delamination in the ray-fill laminate composite. BRIEF DESCRIPTION OF THE DRAWINGS
[00017] The description can be better understood with reference to the following detailed description, taken in conjunction with the accompanying drawings, which illustrate preferred and exemplary modalities, but which are not necessarily drawn to scale, in which:
[00018] FIG. 1 is an illustration of a perspective view of an aircraft that can incorporate one or more composite assemblies having one or more composite structures in the form of a ray-filled laminated composite of the description; FIG. 2A is an illustration of a flowchart of an aircraft service production and execution method; FIG. 2B is an illustration of an aircraft block diagram; FIG. 3 is an illustration of a block diagram of a composite assembly showing an embodiment of a ray-filled laminated composite of the description; FIG. 4A is an illustration of a perspective view of a composite structure in the form of a T-reinforcement having a ray-filled region filled with a ray-filled laminated composite embodiment of the description; FIG. 4B is an illustration of an enlarged, fragmented front sectional view of the ray-filled laminated composite of FIG. 4A in a composite assembly; FIG. 5 is an illustration of a front sectional view, enlarged, of one of the modalities of a ray-filled laminated composite of the description having a geometrically shaped filling element and a point element; FIG. 6 is an illustration of an enlarged front sectional view of another embodiment of a ray-filled laminated composite of the description having two geometrically shaped filling elements and a point element; FIG. 7 is an illustration of a front sectional view, enlarged, of another embodiment of a ray-filled laminated composite of the description having two filling elements geometrically shaped and at the tip element; and, FIG. 8 is an illustration of a flowchart of an example embodiment of the method of description. DETAILED DESCRIPTION
[00019] The described modalities will now be described more fully hereinafter with reference to the attached drawings, in which some modalities, but not all of the described modalities, are shown. In fact, several different modalities can be provided and should not be interpreted as limited to the modalities described here. On the contrary, these modalities are provided in such a way that this description will be thorough and will fully convey the scope of the description to those skilled in the art.
[00020] Now with reference to the figures, FIG. 1 is an illustration of a perspective view of an aircraft 10 that can incorporate one or more composite assemblies 26 with one or more composite structures 28. Composite structure 28 (see FIG. 1) can incorporate a modality of a laminated composite of ray fill 70 (see FIGS. 3, 4A-4B, 5-7), such as, for example, a ray fill laminate composite 70a (see FIG. 5), a ray fill laminate composite 70b (see FIG. 6), or a ray-fill laminate composite 70c (see FIG. 7), formed by one or more embodiments of a method 150 (see FIG. 8) of the description.
[00021] As shown in FIG. 1, aircraft 10 comprises a fuselage 12, a nose 14, a cockpit 16, wings 18, one or more propulsion units 20, a vertical tail portion 22, and horizontal tail portions 24. Aircraft 10 shown in FIG. 1 is generally representative of a commercial passenger aircraft having one or more composite assemblies 26 with one or more composite structures 28. However, the teachings of the described modalities can be applied to other passenger aircraft, filler aircraft, military aircraft, helicopter, and other types of aircraft or air vehicles, as well as aerospace vehicles, satellites, space launch vehicles, rockets, and other aerospace vehicles, as well as boats and other vessels, trains, automobiles, trucks, buses, or other appropriate structures having one or more composite sets 26 with one or more composite structures 28 that can incorporate a ray-fill laminate composite modality 70 (see FIGS. 3, 4A-4B, 5-7) made with one or more modalities of method 150 (see Figure 8) of the description.
[00022] FIG. 2A is an illustration of a flowchart of an aircraft service production and execution method 30. FIG. 2B is an illustration of a block diagram of an aircraft 50. With reference to FIGS. 2A-2B, modalities of the description can be described in the context of an aircraft service production and delivery method 30, as shown in FIG. 2A, and the aircraft 50, as shown in FIG. 2B. During pre-production, the aircraft service production and delivery method 30, for example, may include aircraft specification and design 32 and material acquisition 34. During production, the manufacture of components and subassemblies 36 and integration of systems 38 of aircraft 50 take place. Then, aircraft 50 can pass through certification and delivery 40 in order to be put into service 42. While in service 42 by a customer, aircraft 50 can be scheduled for routine maintenance and service 44, which may also include modification , reconfiguration, remodeling, and other appropriate services.
[00023] Each of the processes of an aircraft service production and execution method 30 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 subcontractors to the main system; a third party may include, without limitation, any number of vendors, subcontractors and suppliers; and, an operator may be an airline, rental company, military organization, service organization and other appropriate operators.
[00024] As shown in FIG. 2B, the aircraft 50 produced by the aircraft service production and delivery method 30, for example, may include a fuselage 52 with a plurality of high-level systems 54 and an interior 56. Examples of the plurality of high-level systems 54 they may include one or more of a propulsion system 58, an electrical system 60, a hydraulic system 62, and an environmental system 64. Any number of other systems may also be included. Although an aerospace example is shown, the principles of the invention can be applied to other industries, such as the automotive industry.
[00025] Methods and systems incorporated here may be employed during any one or more of the stages of the production and service method 30. For example, components or subassemblies corresponding to the manufacture of components and subassemblies 36 may be produced or manufactured in a similar manner to those components or subassemblies produced while the aircraft 50 is in service 42. Also, one or more apparatus modalities, the method modalities, or a combination thereof, may be used during the manufacture of components and subassemblies 36 and systems integration 38, for example, by substantially speeding up the assembly, or cost reduction, of aircraft 50. Similarly, one or more of the apparatus modalities, the method modalities, or a combination thereof, may be used while the aircraft 50 is in service 42 , for example, and, without limitation, for routine maintenance and service 44.
[00026] In one embodiment of the description, a laminated composite of ray fill 70 is provided (see FIGS. 3, 4A-4B, 5-7), that is, "noodle", to fill a ray fill region 72 (see FIGS. 3, 4A-4B), ie "noodle region", for a composite structure 28 (see FIGS. 3, 4A-4B) in a composite assembly 26 (see FIGS. 3, 4B). FIG. 3 is an illustration of a block diagram of a composite assembly 26, such as an aircraft composite assembly 26a, showing an embodiment of a ray-filled laminated composite 70 of the description.
[00027] As shown in FIG. 3, composite assembly 26 comprises a composite structure 28 having a radius fill region 72. As further shown in FIG. 3, the composite structure 28 comprises a ray-filled laminate composite 70 that is adjacent to the envelope folds 84a, envelope folds 84b and envelope folds 92a of the composite structure 28.
[00028] FIG. 4A is an illustration of a perspective view of a composite structure 28, such as in the form of a T-reinforcement 76, having a radius-filling region 72 filled with a ray-fill composite laminate 70 embodiment of the description. FIG. 4B is an illustration of an enlarged, fragmented front sectional view of the ray-filled laminate composite 70 of FIG. 4A in a composite assembly 26, such as an aircraft composite assembly 26a. As shown in FIG. 4B, the ray-fill laminate composite 70, as in the form of ray-fill laminate composite 70a, preferably has a configuration 74 substantially corresponding to the size and shape of the ray-fill region 72 of the composite structure 28.
[00029] As shown in FIG. 4A, the composite structure 28, as in the form of T-reinforcement 76, comprises vertical webs 78, horizontal flanges 80, and flange-web transitions 82 radially surrounding the ray-filled laminate composite 70. The vertical webs 78 (see 4A-4B) and the horizontal flanges 80 (see FIGS. 4A-4B) preferably comprise stacked composite folds 84 (see FIGS. 4A-4B), such as housing folds 84a, 84b (see FIGS. 3, 4B), adjacent to the ray-fill laminate composite 70 (see FIGS. 3, 4A-4B). The casing folds 84a, 84b (see FIG. 4B) preferably have a radial orientation 86 (see FIG. 4B) extending in a vertical direction 118b (see FIG. 4B) or substantially vertical direction. As still shown in FIG. 4A, the horizontal flanges 80 of the T-reinforcement 76 can be joined on an interface 88 for one or more base laminates 90 and / or the cover panels 96, for example, a cover-reinforcement interface.
[00030] As shown in FIG. 4B, the one or more base laminates 90 may comprise stacked composite base folds 92, such as in the form of envelope folds 92a, adjacent to the ray-fill laminate composite 70. The envelope folds 92a (see FIGS. 3 , 4B) preferably have a radial orientation 94 (see FIGS. 4B, 5-7) extending in a horizontal direction 118a (see FIG. 4B). As still shown in FIG. 4B, composite assembly 26, as in the form of aircraft composite assembly 26a, shows the ray-filled laminated composite 70 surrounded by stringers 98.
[00031] As shown in FIGS. 3, 4B, the ray-filled laminate composite 70 comprises a geometrically shaped filling element 100 having a geometric shape 102 (see FIG. 4B), an optional tip element 104, base portions 106a, 106b (see FIG 4B), upper portion 106c (see FIG. 4B), and a stacked fold set 108. The ray-filled laminate composite 70 (see FIGS. 3, 4B, 5-7) can incorporate one or more elements geometrically shaped fillers 100 (see FIGS. 3, 4B, 5-7), positioned within the stacked fold set 108 (see FIGS. 3, 4B, 5-7) of the radius fill laminate composite 70 (see Figures 3, 4B, 5-7).
[00032] The ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) can be formed of a composite material by any appropriate means including, but not limited to, pultrusion, extrusion, manual laying, laying automatic, or any other suitable forming process, as described in more detail below. The ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) can be formed by first forming the stacked fold set 108 (see FIGS. 3, 4B, 5-7). As shown in FIG. 3, the stacked fold set 108 preferably comprises a plurality of laminated ray fill folds 110 (see also FIGS. 4B, 5-7) (see also FIG. 4B), 110b (see also FIG 4B), 110c (see also FIG. 6), and / or HOd (see also FIG. 7) cut to a desired width 132 and having a desired fold orientation 134.
[00033] The desired width 132 (see FIG. 3) chosen from large to small widths and can be chosen to conform to the size and shape of a radius 114 (see FIG. 4B) of the laminate filling composite rays 70 (see FIG. 4B) which is finally formed. The desired fold orientation 134 (see FIG. 3) can be configured in any desired fold direction. For example, the desired fold orientation 134 can include, without limitation, such fold orientations as +45 degrees / - 45 degrees, +50 degrees / -50 degrees, 0 degrees, 90 degrees, or other suitable fold orientation. For example, when used here, "+45 degrees" means that a fold is rotated by 45 degrees clockwise and "-45 degrees" means a fold is rotated by 45 degrees counterclockwise. The choice of the desired fold orientation 134 (see FIG. 3) for the stacked fold set 108 (see FIGS. 3, 4B) depends on the desired stiffness of the ray-fill laminate composite 70 (see FIGS. 3, 4B) with respect to the stiffness of the surrounding casing folds 84a, 84b, 92a (see FIGS. 3, 4B).
[00034] As shown in FIGS. 3, 4B, the stacked fold assembly 108 preferably comprises a first portion 108a and a second portion 108b. Where more than one of the geometrically shaped filling elements 100 (see FIGS. 6, 7) are formed in the ray-filled laminate composite 70 (see FIGS. 6, 7), one or more of the additional portion 108c ( see FIG. 6), additional portion 108d (see FIG. 7), or other additional portions, can be formed from the second portion 108b (see FIGS. 5-7).
[00035] The stacked fold set 108 (see FIGS. 3, 4B) of the ray-fill composite laminate 70 (see FIGS. 3, 4B) can be made of the same material or similar material of resin and fibers, used to form components of composite assembly 26 (see FIGS. 3, 4B), such as composite structure 28 (see FIGS. 3, 4B), stringers 98 (see FIG. 4B), base laminates 90 (see FIG. 4B) and cover panel 96 (see FIG. 4B). For example, stacked composite folds 84, stacked composite base folds 92, and the plurality of laminated ray fill folds 110 (see FIG. 3) 110a (see FIG. 4B), 110b (see FIG. 4B), 110c (see FIG. 6), and / or 110d (see FIG. 7) can be formed of a reinforcement material surrounded by, and supported within, a matrix material, such as, for example, example, a prepreg material.
[00036] The reinforcement material may comprise high strength fibers, such as glass or carbon fibers, graphite, aromatic polyamide fiber, fiberglass, or other suitable reinforcement material. The matrix material may comprise various polymer or resin materials, such as epoxy, polyester, vinyl ester resins, polyetheretherketone polymer (PEEK), polyetheretherketone polymer (PEKK), bismaleimide, or other suitable matrix material. When used here, “pre-impregnated” means a woven or plaited cloth or ribbon material of the clothing type, for example, glass or carbon fibers, which have been impregnated with an uncured or partially cured resin, which is sufficiently flexible to be shaped into a desired shape, "cured", for example, by applying heat in an oven or an autoclave or other heating devices, to harden the resin forming a strong, rigid fiber-reinforced structure.
[00037] Stacked composite folds 84, stacked composite base folds 92, and the plurality of laminated radius fill folds 110a (see FIG. 3) (see FIG. 4B), 110b (see Figure 4B), 110c (see Figure 6), and / or 110d (see Figure 7) can be in the form of a pre-impregnated unidirectional tape, unidirectional fiber tape, reinforced plastic tape with carbon fibers (CFRP), or other appropriate tape; a carbon fiber reinforced plastic (CFRP) fabric, a prepreg fabric, a woven cloth including a woven carbon fiber cloth, or other suitable fabric; a combination of a ribbon or a fabric thereof; or other suitable composite material.
[00038] As discussed in more detail below with respect to method 150, the first portion 108a (see FIG. 3) of the stacked fold assembly 108 (see FIG. 3) can comprise three or four folds with preferably at least one fold having a zero degree (0o) fold orientation. If an automatic laying process is used to form the stacked fold set 108 (see FIG. 3), the plurality of stacks 110 comprising the rolled radius fill folds 110a (see FIG. 4B), 110b (see the FIG. 4B), 110c (see FIG. 6), and / or 110d (see FIG. 7) can be seated with single folds in any desired fold orientation 134 (see FIG. 3).
[00039] As shown in more detail in FIGS. 3, 4B, 5-6 the ray-filled laminate composite 70 can optionally comprise a tip element 104. The tip element 104 (see FIGS. 3, 4B, 5-6) is preferably comprised of a plurality of fibers unidirectional fiber tape, unidirectional pre-impregnated tape, unidirectional composite tow, split unidirectional tape, carbon fiber reinforced plastic (CFRP) tape, carbon fiber reinforced plastic (CFRP) ), a prepreg fabric, a woven cloth including a woven carbon fiber cloth, chopped fiber, a combination thereof, or other suitable fiber material.
[00040] Nib 104 (see FIGS. 3, 4B, 5-6) preferably has a 105 configuration (see FIGS. 4B, 5-6) comprising one of substantially an arrowhead configuration 105a (see Figure 5), a multiple triangle configuration 105b (see Figure 6), or other appropriate configuration. As shown in FIG. 5, the tip element 104, as in the form of tip element 104a, is positioned on an upper portion 122 of the stacked fold assembly 108, such as the upper portion 122 of the second portion 108b of the stacked fold assembly 108. As still shown in FIG. 5, the tip element 104a has a configuration 105 in the form of a substantially arrowhead configuration 105a.
[00041] As shown in FIG. 6, the tip element 104, as in the form of tip element 104b, is positioned over an upper portion 122 of the stacked fold assembly 108, as is the upper portion 122 of the additional portion 108c of the stacked fold assembly 108. As still shown in FIG. 6, the tip element 104b has a configuration 105 in the form of a multiple triangle configuration 105b.
[00042] As shown in more detail in FIGS. 3, 4B, 5-7, the ray-fill laminate composite 70 comprises a geometrically shaped filler element 100, such as in the form of a first geometrically shaped filler element 100a, positioned at a desired location 120 (see FIGS. 5 -7) on a first portion 108a (see FIGS. 5-7) of the stacked fold assembly 108. As shown in FIG. 5, in one embodiment, the desired location 120 on the first portion 108a of the stacked fold assembly 108 is preferably a central location 120a or a substantially central location on the first portion 108a. However, other desired suitable locations can also be chosen. Since delamination or cracking in laminated composite ray fillings, it can typically start in the upper portion, such as in the upper portion half or third portion of the upper portion, of the ray-filled laminate composite, preferably the one or more geometrically shaped filling elements 100 (see FIGS. 4B, 5-7) are positioned or located in the upper portion, such as half of the upper portion or the third portion of the upper portion, of the ray-filled laminate composite 70 (see FIGS. 4B, 5-7).
[00043] In addition, preferably the second portion 108b (see FIGS. 4B, 5-7) of the stacked fold set 108 (see FIGS. 4B, 5-7) in the upper portion, such as half of the upper portion or the third part of the upper portion, of the laminated ray-filling composite 70 (see FIGS. 4B, 5-7), is deformed or shaped by one or more geometrically shaped filling elements 100 (see FIGS. 4B, 5 -7). The one or more geometrically shaped filling elements 100 (see FIGS. 4B, 5-7) preferably deform or bend the second portion 108b (see FIGS. 4B, 5-7), and any additional portions 108c (see FIG 6), 108d (see FIG. 7), of the stacked fold set 108 (see FIGS. 4B, 5-7), which are stacked on the respective geometrically shaped filling elements 100 (see FIGS. 4B, 5-7). This deformation causes the laminated radius fill folds 110b (see FIGS. 4B, 4-7), 110c (see FIG. 6), and / or 110d (see FIG. 7) of the second portion 108b ( see Figures 4B, 5-7), and any additional portions 108c (see Figure 6), 108d (see Figure 7), of the stacked fold assembly 108 (see Figures 4B, 5), if bend and change direction and have a steering component 116 (see FIGS. 3, 4B, 5-7) comprising a horizontal direction 118a (see FIGS. 3, 4B, 5-7) and a vertical direction 118b (see Figures 3, 4B, 5-7), so as to substantially coincide with the vertical direction 118b (see Figure 4B) of the casing folds 84a, 84b (see Figure 4B) adjacent to the laminate filler composite. radii 70 (see FIGS. 3, 4B, 5-7). When used here, "horizontal direction" means a horizontal or substantially horizontal direction, and parallel or substantially parallel to a ground level, and perpendicular or substantially perpendicular to a vertical direction. When used here, "vertical direction" means a vertical or substantially vertical direction, and normal or perpendicular or substantially normal or substantially perpendicular, to a horizontal direction.
[00044] As shown in FIG. 3, the ray-filled laminate composite 70 may further comprise one or more additional geometrically shaped filling elements 100, such as the additional geometrically shaped filling element 100b (see also FIG. 6), or the additional geometrically shaped fill 100c (see also FIG. 7), or other appropriate additional geometrically shaped fill element 100. As shown in FIG. 6, the additional geometrically shaped filling element 100b is preferably positioned at a desired location 124 on the second portion 108b and within and below the additional portion 108c. Yet, as shown in FIG. 7, the additional geometrically shaped filling element 100c is preferably positioned in a desired location 126 on the second portion 108b and in and below the additional portion 108d.
[00045] The geometrically shaped filling element 100, 100a (see FIG. 3) and any additional geometrically shaped filling elements, 100, 100b, 100c (see FIG. 3) are each preferably comprised of a plurality unidirectional fiber 101 (see FIG. 3), unidirectional fiber tape, prepreg unidirectional tape, unidirectional composite tow, split unidirectional tape, carbon fiber reinforced plastic (CFRP) tape, one carbon fiber reinforced plastic (CFRP) fabric, a prepreg fabric, a woven cloth including a woven carbon fiber cloth, chopped fiber, a combination thereof, or other suitable fiber material. The unidirectional fibers 101 (see FIG. 3) preferably substantially run down a length of the composite structure 28 (see FIG. 4A).
[00046] In one embodiment, the geometrically shaped filler element 100, 100a (see FIG. 3) and any additional geometrically shaped filler elements, 100, 100b, 100c (see FIG. 3) can be comprised of fibers pultruded unidirectional 101a (see FIG. 3) having a zero degree (0 °) bend orientation. Preferably, the unidirectional pultruded fibers 101a (see FIG. 3) are formed using a pultrusion process and a pultrusion apparatus 130 (see FIG. 3), as discussed in more detail below.
[00047] The geometrically shaped filler element 100, 100a (see FIG. 3) and any additional geometrically shaped filler elements, 100, 100b, 100c (see FIG. 3) preferably each have a geometric shape 102 (see FIGS. 4B, 5-7). The geometric shape 102 (see FIGS. 4B, 5-7) can comprise one of a triangle shape 102a (see FIGS. 4B, 5), a triangle shape with curved vertices 102b (see FIG. 6), an arrowhead shape 102c (see FIG. 7), a triangle shape with removed vertices (not shown), a triangle shape with one or more curved sides (not shown), a radius fill shape (not shown), a semicircle shape (not shown), or other appropriate geometric shape.
[00048] The purpose of the geometrically shaped filling element 100, 100a (see FIG. 3) and any additional geometrically shaped filling elements, 100, 100b, 100c (see FIG. 3), as discussed above, is that of changing the respective direction of the laminated ray fill folds 110b (see FIG. 4B), 100c (see FIG. 6), and / or 110d (see FIG. 7) of the second portion 108b (see FIG 3) and any additional portions 108c, 108d (see FIG. 3) to bend and change direction and have a direction component 116 comprising horizontal direction 118a (see FIGS. 3, 4B, 5-7) and a vertical direction 118b (see FIGS. 3, 4B, 5-7).
[00049] Various embodiments of the ray-fill composite laminate 70 are shown in FIGS. 5-7. Such modalities should not be considered as limiting.
[00050] FIG. 5 is an illustration of a front sectional view, enlarged, of one of the modalities of the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70a, of the description. The ray-filled laminated composite 70a shown in FIG. 5 has a geometrically shaped filler element 100, such as in the form of a first geometrically shaped filler element 100a. The first geometrically shaped filling element 100a (see FIG. 5) preferably has a geometric shape 102 (see FIG. 5) in the form of a triangle shape 102a (see FIG. 5). However, the geometrically shaped filler element 100, as in the form of the first geometrically shaped filler element 100a, may have another suitable geometric shape.
[00051] FIG. 5 shows the base portions 106a, 106b and the upper portion 106c of the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70a. FIG. 5 further shows the stacked composite folds 84, such as in the form of envelope folds 84a, 84b, and the stacked composite base folds 92 of the base laminate 90, such as in the form of envelope folds 92a. The casing folds 84a, 84ba and the casing folds 92a surround the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70a.
[00052] The ray-fill laminate composite 70 (see FIG. 5), as in the form of ray-fill laminate composite 70a (see FIG. 5), preferably has a 74 configuration (see FIG. 5 ) substantially corresponding to the shape and size of the radius fill region 72 (see FIG. 4B) of the composite structure 28 (see FIG. 4B). As shown in FIG. 5, configuration 74 of the ray-fill laminate composite 70 is substantially a triangle shape. However, the ray-fill laminate composite 70 (see FIG. 5) may have another suitable shape or configuration.
[00053] The ray-filled laminated composite 70a shown in FIG. 5 further has a nib element 104, such as in the form of nib element 104a. The pointed element 104a (see FIG. 5) has a configuration 105 (see FIG. 5) in the form of a substantially arrowhead configuration 105a (see FIG. 5). As still shown in FIG. 5, the tip element 104a is preferably positioned at a tip location 112 of the ray-fill laminate composite 70, such as the ray-fill laminate composite 70a. As still shown in FIG. 5, the tip element 104a is preferably positioned on an upper portion 122 of the stacked fold assembly 108, such as the upper portion 122 of the second portion 108b of the stacked fold assembly 108.
[00054] FIG. 5 shows the geometrically shaped filling element 100, such as in the form of the first geometrically shaped filling element 100a, positioned at the desired location 120, such as a central location 120a or substantially central location, on the first portion 108a of the stacked fold assembly 108. However, the geometrically shaped filling element 100 (see FIG. 5), as in the form of the first geometrically shaped filling element 100a (see FIG. 5), can be positioned at another desired appropriate location 120 (see Figure 5) on the first portion 108a (see Figure 5).
[00055] As shown in FIG. 5, the geometrically shaped filler element 100, as in the form of the first geometrically shaped filler element 100a, preferably deforms the second portion 108b of the stacked fold assembly 108, stacked on the first geometrically shaped filler element 100a. This causes the plurality of stacks of laminated ray-fill folds 110b (see FIG. 5) (see FIG. 5) of the second portion 108b (see FIG. 5) to change direction. As still shown in FIG. 5, the laminated radius fill folds 110a preferably each have a direction component 116 comprising a horizontal direction 118a and a vertical direction 118b. Preferably, changing the direction of the rolled radius fill folds 110b (see FIG. 5) of the second portion 108b (see FIG. 5) minimizes a difference in the thermal expansion coefficient (CTE) 136 (see FIG. 3 ) and interlaminar tensile stress 138 (see FIG. 3) between the ray-filled laminated composite 70 (see FIG. 5) and the casing folds 84a, 84b (see FIG. 5) adjacent to the laminated composite of ray fill 70 (see FIG. 5).
[00056] When used here, "thermal expansion coefficient (CTE)" means one of a change in the size or volume of a material in response to a change in the temperature of the material. When used here, "interlaminar tensile stress" means the tension normal to a plurality of folds, for example, ribbon or fabric folds, which tend to pull the folds apart or delaminate them. Minimizing the difference in CTE 136 (see FIG. 3) and interlaminar tensile stress 138 (see FIG. 3) preferably eliminates delamination or results in a reduced delamination 140 (see FIG. 3) of the filler laminate composite radius 70 (see FIG. 5). Such delamination can result from thermal stresses that occur during curing and thermal cycling stages of the composite structure 28 (see FIG. 4B) and / or composite assembly 26 (see FIG. 4B).
[00057] Thus, instead of being stacked in a horizontal direction 118a (see FIG. 4B) throughout the ray-fill laminate composite 70, the laminated ray-fill folds 110b (see FIG. 5) stacked on the geometrically shaped filling element 100 (see FIG. 5) begins to deform or flex to have a direction component 116 (see FIG. 5) comprising the horizontal direction 118a (see FIG. 5) and the vertical direction 118b (see FIG. 5) to match or substantially match or follow the vertical direction 118b (see FIG. 4B) of the casing folds 84a, 84b (see FIGS. 4B, 5) adjacent to the ray-filled laminate composite 70 (see FIG. 5).
[00058] This preferably minimizes the difference in CTE 136 (see FIG. 3) between the ray-filled laminated composite 70 (see FIG. 5) and the surrounding folds 84a, 84b (see FIG. 5) to the ray-fill laminate composite 70 (see FIG. 5). This is because the laminated radius fill folds 110b (see FIG. 5) of the radius fill laminate composite 70 (see FIG. 5) and the casing folds 84a, 84b (see FIG. 5) have the same or similar vertical orientation. In addition, for laminated radius fill folds 110b (see FIG. 5) stacked on the geometrically shaped fill element 100a (see FIG. 5), a radial orientation 114 (see FIG. 5) of the second 108b (see FIG. 5) of the ray-fill laminate composite 70 (see FIG. 5) preferably substantially corresponds to a radial orientation 86 (see FIG. 5) of the stacked composite folds 84 (see FIG. 5) , such as casing folds 84a, 84b (see FIG. 5).
[00059] FIG. 6 is an illustration of an enlarged front sectional view of another embodiment of the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70b, of the description. The ray-filled laminated composite 70b shown in FIG. 6 has two geometrically shaped filling elements 100, such as in the form of the first geometrically shaped filling element 100a, and the additional geometrically shaped filling element 100b. The first geometrically shaped filling element 100a (see FIG. 6) preferably has a geometric shape 102 (see FIG. 6) in the form of a triangle shape 102a (see FIG. 6). The additional geometrically shaped filler element 100b (see FIG. 6) preferably has a geometric shape 102 (see FIG. 6) in the form of a triangle shape with curved vertices 102b (see FIG. 6). However, the geometrically shaped filling elements 100, such as in the form of the first geometrically shaped filling element 100a and the additional geometrically shaped filling element 100b, may each have another suitable geometric shape.
[00060] FIG. 6 shows the base portions 106a, 106b and the upper portion 106c of the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70b. FIG. 6 further shows the stacked composite folds 84, such as in the form of envelope folds 84a, 84b, and the stacked composite base folds 92 of the base laminate 90, such as in the form of envelope folds 92a. As shown in FIG. 6, casing folds 84a, 84b and casing folds 92a surround the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70b.
[00061] The ray-fill laminate composite 70 (see FIG. 6), as in the form of ray-fill laminate composite 70b (see FIG. 6), preferably has a 74 configuration (see FIG. 6 ) substantially corresponding to the shape and size of the radius fill region 72 (see FIG. 4B) of the composite structure 28 (see FIG. 4B). As shown in FIG. 6, configuration 74 of the ray-fill laminate composite 70 is substantially a triangle shape. However, the ray-fill laminate composite 70 (see FIG. 6) may have another suitable shape or configuration.
[00062] The ray-filled laminated composite 70b shown in FIG. 6 further has a point element 104, such as in the form of point element 104b. As shown in FIG. 6, the tip element 104b has a configuration 105 in the form of a multiple triangle configuration 105b. As still shown in FIG. 6, the tip element 104b is preferably positioned at a tip location 112 of the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70b. As still shown in FIG. 6, the tip element 104b is preferably positioned on an upper portion 122 of the stacked fold assembly 108, such as the upper portion 122 of the additional portion 108c of the stacked fold assembly 108. The tip element 104b (see FIG. 6 ) can be formed via a pultrusion or other appropriate process. If a matrix is used, a vertical fold 125 (see FIG. 6) of fabric or ribbon oriented with the height in the vertical direction 118b (see FIG. 6) and the width in the horizontal direction 118a (see FIG. 6) , can be used in addition to, or in place of, the tip element 104 (see FIG. 6) which is pultruded. The vertical fold 125 (see FIG. 6) would preferably be a first portion of the ray-filled laminated composite 70b to be placed within a matrix.
[00063] FIG. 6 shows the geometrically shaped filling element 100, such as in the form of the first geometrically shaped filling element 100a, positioned at the desired location 120, such as the central location 120a or substantially central location, on the first portion 108a of the stacked fold assembly 108. However, the geometrically shaped filler element 100 (see FIG. 6), as in the form of the first geometrically shaped filler element 100a (see FIG. 6), can be positioned at another desired appropriate location on the first portion 108a (see FIG. 6).
[00064] FIG. 6 further shows the geometrically shaped filling element 100, as in the form of the additional geometrically shaped filling element 100b, positioned in the desired location 124 on the second portion 108b of the stacked fold set 108. Preferably, the desired location 124 (see FIG. 6) is a central location or substantially central location on the second portion 108b (see FIG. 6). However, the geometrically shaped filler element 100 (see FIG. 6), as in the form of the additional geometrically shaped filler element 100b (see FIG. 6), can be positioned at another desired appropriate location on the second portion 108b (see FIG. 6).
[00065] As shown in FIG. 6, the geometrically shaped filler element 100, as in the form of the first geometrically shaped filler element 100a, preferably deforms the second portion 108b of the stacked fold assembly 108, stacked on the first geometrically shaped filler element 100a. This causes the plurality of stacks of laminated radius fill folds 110b (see FIG. 6) (see FIG. 6) of the second portion 108b (see FIG. 6) to change direction. The laminated radius fill folds 110a (see FIG. 6) are oriented in the horizontal direction 118a (see FIG. 6) and change direction or deform to laminated radius fill folds 110b (see FIG. 6) having a steering component 116 (see FIG. 6) comprising the horizontal direction 118a and the vertical direction 118b (see FIG. 6).
[00066] As still shown in FIG. 6, the geometrically shaped filler element 100, such as in the form of the additional geometrically shaped filler element 100b, preferably deforms the additional portion 108c stacked on top of the geometrically shaped filler element 100b. This causes the plurality of stacks of laminated ray fill folds 110c (see FIG. 6) (see FIG. 6) of the additional portion 108c (see FIG. 6) to change direction. The laminated radius fill folds 110c (see FIG. 6) warp or bend to have a direction component 116 (see FIG. 6) comprising the horizontal direction 118a (see FIG. 6) and the vertical direction 118b ( see FIG. 6).
[00067] Preferably, changing the direction of the laminated ray fill folds 110b (see FIG. 6) of the second portion 108b (see FIG. 6) and changing the direction of the laminated ray fill folds 110c (see Figure 6) of the additional portion 108c (see Figure 6) helps both to minimize a difference in CTE 136 (see Figure 3) and the interlaminar tensile stress 138 (see Figure 3) between the laminated composite ray filler 70 (see FIG. 6) and the casing folds 84a, 84b (see FIG. 6) adjacent to the ray filler laminate composite 70 (see FIG. 6). Minimizing the difference in CTE 136 (see FIG. 3) and interlaminar tensile stress 138 (see FIG. 3) preferably eliminates delamination or results in a reduced delamination 140 (see FIG. 3) of the filler laminate composite radius 70 (see FIG. 5). Such delamination may result from thermal stresses that occur during curing and thermal cycling stages of the composite structure 28 (see FIG. 4B) and / or composite assembly 26 (see FIG. 4B).
[00068] Thus, instead of being stacked in the horizontal direction 118a (see FIG. 4B) through the entire radius fill laminate composite 70 (see FIG. 6), the laminated radius fill folds 110b (see FIG. 6) stacked on the first geometrically shaped filler element 100a (see FIG. 6) and the laminated radius filler folds 110c (see FIG. 6) stacked on the additional geometrically shaped filler 100b (see Figure 6) both begin to deform or flex to have a steering component 116 (see Figure 6) comprising the horizontal direction 118a and the vertical direction 118b (see Figure 6) to match or substantially match or follow the vertical direction 118a (see FIG. 4B) of the casing folds 84a, 84b (see FIGS. 4B, 6) adjacent to the ray-filled laminate composite 70 (see FIG. 6).
[00069] This preferably minimizes the difference in CTE 136 (see FIG. 3) between the ray-filled laminate composite 70 (see FIG. 6) and the enclosure folds 84a, 84b (see FIG. 6) adjacent to the ray-fill laminate composite 70 (see FIG. 6). This is because both the laminated ray filler folds 110b (see FIG. 6) and the laminated ray filler folds 110c (see FIG. 6) of the ray-fill laminate composite 70 (see FIG. 6) , and the casing folds 84a, 84b (see FIG. 6), have the same or similar vertical orientation.
[00070] In addition, for the laminated radius filler folds 110b (see FIG. 6) stacked on the geometrically shaped filler 100a (see FIG. 6), and for the laminated radius filler folds 110c ( see FIG. 6) stacked on the additional geometrically shaped filling element 100b (see FIG. 6), the radial orientation 114 (see FIG. 6) of the second portion 108b (see FIG. 6) and the additional portion 108c (see FIG. 6) of the ray-fill laminate composite 70 (see FIG. 5) preferably substantially corresponds to the radial orientation 86 (see FIG. 6) of the stacked composite folds 84 (see FIG. 6) , such as casing folds 84a, 84b (see FIG. 6).
[00071] FIG. 7 is an illustration of an enlarged front sectional view of another embodiment of the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70c, of the description. The ray-filled laminated composite 70c shown in FIG. 7 has two geometrically shaped filling elements 100, such as in the form of the first geometrically shaped filling element 100a, and the additional geometrically shaped filling element 100c.
[00072] The first geometrically shaped filling element 100a (see FIG. 7) preferably has a geometric shape 102 (see FIG. 7) in the form of a triangle shape 102a (see FIG. 7). The additional geometrically shaped filler element 100c (see FIG. 7) preferably has a geometric shape 102 (see FIG. 7) in the form of an arrowhead shape 102c (see FIG. 7). However, the geometrically shaped filler element 100, such as in the form of the first geometrically shaped filler element 100a and the additional geometrically shaped filler element 100c, may each have another suitable geometric shape.
[00073] FIG. 7 shows the base portions 106a, 106b and the upper portion 106c of the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70c. FIG. 7 further shows the stacked composite folds 84, such as in the form of envelope folds 84a, 84b, and the stacked composite base folds 92 of the base laminate 90, such as in the form of envelope folds 92a. As shown in FIG. 7, the casing folds 84a, 84b and the casing folds 92 surround the ray-fill laminate composite 70, such as in the form of ray-fill laminate composite 70c.
[00074] The ray-fill laminate composite 70 (see FIG. 7), as in the form of ray-fill laminate composite 70c (see FIG. 7), preferably has a 74 configuration (see FIG. 7 ) substantially corresponding to the shape and size of the radius fill region 72 (see FIG. 4B) of the composite structure 28 (see FIG. 4B). As shown in FIG. 7, configuration 74 of the ray-fill laminate composite 70 is substantially a triangle shape. However, the ray-fill laminate composite 70 (see FIG. 7) may have another suitable shape or configuration.
[00075] FIG. 7 shows the geometrically shaped filling element 100, as in the form of the first geometrically shaped filling element 100a, positioned at the desired location 120, such as the central location 120a or substantially central location, on the first portion 108a of the stacked fold assembly 108. However, the geometrically shaped filling element 100, such as in the form of the first geometrically shaped filling element 100a, can be positioned in another desired appropriate location on the first portion 108a (see FIG. 7).
[00076] The ray-filled laminated composite 70c shown in FIG. 7 does not have a pointed element 104 (see FIGS. 5-6). In place of the tip element 104 (see FIGS. 5-6), FIG. 7 shows the ray-fill laminate composite 70c having the geometrically shaped filling element 100, as in the form of the additional geometrically shaped filling element 100c, positioned in a desired location 126 on the second portion 108b of the stacked fold assembly 108. Preferably, the desired location 126 (see FIG. 7) is a central or substantially central location on the second portion 108b (see FIG. 7). However, the geometrically shaped filler element 100, such as in the form of the additional geometrically shaped filler element 100c, can be positioned in another desired appropriate location on the second portion 108b (see FIG. 7).
[00077] As shown in FIG. 7, the geometrically shaped filler element 100, such as in the form of the first geometrically shaped filler element 100a, preferably deforms the second portion 108b of the stacked fold assembly 108, stacked on the first geometrically shaped filler element 100a. This causes the plurality of stacks of laminated radius fill folds 110b (see FIG. 7) (see FIG. 7) of the second portion 108b (see FIG. 7) to change direction. The plurality of piles 110 (see FIG. 7) of laminated radius fill folds 110a (see FIG. 7) are oriented in the horizontal direction 118b (see FIG. 4B) and change direction or deform to folds of rolled beam fill 110b (see FIG. 7) having a steering component 116 (see FIG. 7) comprising the horizontal direction 118a and the vertical direction 118b (see FIG. 7).
[00078] As still shown in FIG. 7, the geometrically shaped filler element 100, as in the form of the additional geometrically shaped filler element 100c, preferably deforms an additional portion 108d of the stacked fold assembly 108 stacked on the additional geometrically shaped filler element 100c. This causes the plurality of stacks of laminated radius fill folds 110d (see FIG. 7) (see FIG. 7) of the additional portion 108d (see FIG. 7) to change direction. The laminated radius fill folds 110d (see FIG. 7) warp or bend to have a direction component 116 (see FIG. 7) comprising the horizontal direction 118a (see FIG. 7) and the vertical direction 118b ( see FIG. 7).
[00079] Preferably, changing the direction of the laminated ray-fill folds 110b (see FIG. 7) of the second portion 108b (see FIG. 7) and changing the direction of the laminated ray-fill folds 110d (see Figure 7) of the additional portion 108d (see Figure 7) helps both to minimize a difference in CTE 136 (see Figure 3) and the interlaminar tensile stress 138 (see Figure 3) between the laminated composite radius filler 70 (see FIG. 7) and the casing folds 84a, 84b (see FIG. 7) adjacent to the radius filler laminate 70 (see FIG. 7). Minimizing the difference in CTE 136 (see FIG. 3) and interlaminar tensile stress 138 (see FIG. 3) preferably eliminates delamination or results in a reduced delamination 140 (see FIG. 3) of the filler laminate composite radius 70 (see FIG. 7). Such delamination may result from thermal stresses that occur during curing and thermal cycling stages of the composite structure 28 (see FIG. 4B) and / or composite assembly 26 (see FIG. 4B).
[00080] Thus, instead of being stacked in the horizontal direction 118a (see FIG. 4B) through the entire radius fill laminate composite 70 (see FIG. 7), the laminated radius fill folds 110b (see Figure 7) stacked on the first geometrically shaped filler element 100a (see Figure 7) and the laminated radius filler folds 110d (see Figure 7) stacked on the additional geometrically shaped filler element 100c (see Figure 7), both start to deform or flex to have a steering component 116 (see Figure 7) comprising the horizontal direction 118a (see Figure 7) and the vertical direction 118b (see FIG. 7) to match or substantially match or follow the vertical direction 118b (see FIG. 4B) of the casing folds 84a, 84b (see FIGS. 4B, 7) adjacent to the ray-fill laminate composite 70 (see FIG. 7).
[00081] This preferably minimizes the difference in CTE 136 (see FIG. 3) between the ray-filled laminate composite 70 (see FIG. 7) and the enclosure folds 84a, 84b (see FIG. 7) adjacent to the ray-fill laminate composite 70 (see FIG. 7). This is because both the laminated radius fill folds 110b (see FIG. 7) and the laminated radius fill folds 110d (see FIG. 7) of the radius fill laminate composite 70 (see FIG. 7) , and the casing folds 84a, 84b (see FIG. 7), have the same or similar vertical orientation.
[00082] In addition, for laminated radius fill folds 110b (see FIG. 7) stacked on the first geometrically shaped filler 100a (see FIG. 7), and for laminated radius fill folds 110d (see FIG. 7) stacked on top of the additional geometrically shaped filling element 100c (see FIG. 7), the radial orientation 114 (see FIG. 7) of the second portion 108b (see FIG. 7) and the portion additional 108d (see FIG. 7) of the ray-fill laminate composite 70 (see FIG. 7) preferably substantially corresponds to the radial orientation 86 (see FIG. 7) of the stacked composite folds 84 (see FIG. 7 ), such as housing folds 84a, 84b (see FIG. 7).
[00083] In another embodiment of the description, a composite aircraft assembly 26a (see FIGS. 1, 4B) is provided for use on an aircraft 10 (see FIG. 1). The composite aircraft assembly 26a (see FIGS. 1, 4B) comprises a composite structure 28 (see FIGS. 1, 4B). Composite structure 28 (see FIG. 4B) comprises a radius fill region 72 (see FIG. 4B) and a plurality of enclosure folds 84a, 84b, 92a (see FIG. 4B) adjacent to the fill region radius 72 (see FIG. 4B).
[00084] The aircraft composite assembly 26a (see FIG. 4B) further comprises the ray-filled laminated composite 70 (see FIG. 4B) having the configuration 74 (see FIG. 4B) substantially corresponding to the filling region radius 72 (see FIG. 4B) and fill in the radius fill region 72 (see FIG. 4B). The ray-filled laminated composite 70 (see FIG. 4B) comprising the stacked fold set 108 (see FIG. 4B). The stacked fold set 108 (see FIG. 4B) comprises the plurality of laminated ray-fill folds 110 (see FIG. 4B) 110a (see FIG. 4B), 110b (see FIG. 4B) , 110c (see FIG. 6), 110d (see FIG. 7), cut to a desired width 132 (see FIG. 3) and having a desired fold orientation 134 (see FIG. 3). Specific features of the stacked fold set 108 (see FIG. 4B) are discussed in detail above and apply equally to this embodiment of the composite aircraft set 26a (see FIG. 4B).
[00085] The ray-filled laminate composite 70 (see FIG. 4B) further comprises the geometrically shaped filling element 100 (see FIG. 4B) positioned at the desired location 120 (see FIG. 5) on the first portion 108a (see FIGS. 4B, 5) of the stacked fold assembly 108 (see FIG. 4B). The geometrically shaped filler element 100 (see FIG. 4B) deforms the second portion 108b (see FIG. 4B) of the stacked fold assembly 108 (see FIG. 4B) stacked on the geometrically shaped filler element 100 (see Fig. 4B), so that the laminated radius fill folds 110b (see FIG. 4B) of the second portion 108b (see FIG. 4B) of the stacked fold assembly 108 (see FIG. 4B) change direction and have a steering component 116 (see FIG. 4B) comprising the horizontal direction 118a (see FIGS. 4B, 5) and the vertical direction 118b (see FIGS. 4B, 5).
[00086] The ray-fill laminate composite 70 (see FIGS. 6-7) of the ray-fill laminate composite 70 (see FIG. 4B) of the aircraft composite assembly 26a (see FIG. 4B) can comprise still one or more additional geometrically shaped filling elements, 100b (see FIG. 6), 100c (see FIG. 7). Each of the one or more additional geometrically shaped filling elements, 100b (see FIG. 6), 100c (see FIG. 7), can preferably be positioned at a desired location 124 (see FIG. 6) or one desired location 126 (see FIG. 7), respectively, in one or more additional portions 108c (see FIG. 6), 108d (see FIG. 7), respectively, of the stacked fold set 108 (see FIGS. 6-7). In addition, each of the one or more additional geometrically shaped filling elements, 100b (see FIG. 6), 100c (see FIG. 7) still deforms one or more respective additional portions 108c (see FIG. 6), 108d (see FIG. 7) of the stacked fold set 108 (see FIGS. 6-7) stacked on the respective one or more additional geometrically shaped filling elements, 100b (see FIG. 6), 100c (see Figure 7).
[00087] As discussed above, each geometrically shaped filling element 100 (see FIGS. 5-7) is preferably comprised of a plurality of unidirectional fibers 101 (see FIG. 3), a unidirectional fiber tape, a unidirectional tape prepreg, a composite unidirectional tow, a split unidirectional tape, a carbon fiber reinforced plastic (CFRP) tape, a carbon fiber reinforced plastic fabric (CFRP), a prepreg fabric, a cloth fabric including a woven carbon fiber cloth, chopped fiber, a combination thereof, or other suitable fiber material.
[00088] More preferably, each geometrically shaped filling element 100 (see FIGS. 5-7) can be comprised of pultruded unidirectional fibers 101a (see FIG. 3) having a zero degree (0 °) fold orientation. Preferably, the unidirectional pultruded fibers 101a (see FIG. 3) are formed using a pultrusion process and a pultrusion apparatus 130 (see FIG. 3), as discussed in more detail below.
[00089] As discussed above, the geometrically shaped filling element 100 (see FIGS. 3, 4B, 5-7) preferably has a geometric shape 102 (see FIGS. 4B, 5-7). The geometric shape 102 (see FIGS. 4B, 5-7) can comprise one of a triangle shape 102a (see FIGS. 4B, 5), a triangle shape with curved vertices 102b (see FIG. 6), an arrowhead shape 102c (see FIG. 7), a triangle shape with removed vertices (not shown), a triangle shape with one or more curved sides (not shown), a radius fill shape (not shown), a semicircle shape (not shown), or other appropriate geometric shape.
[00090] The ray-fill laminate composite 70 (see FIGS. 4B, 5) of the aircraft composite assembly 26a (see FIG. 4B) can further comprise a tip member 104 (see FIGS. 4B, 5) positioned over an upper portion 122 (see FIG. 5) of the stacked fold assembly 108 (see FIG. 5), as well as the upper portion 122 (see FIG. 5) of the second portion 108b (see FIG. 5 ) of the stacked fold set 108 (see FIG. 5). The pointed element 104 (see FIGS. 4B, 5) is preferably comprised of a plurality of unidirectional fibers, a unidirectional fiber strip, a pre-impregnated unidirectional tape, a unidirectional composite tow, a divided unidirectional tape, carbon fiber reinforced plastic (CFRP), a carbon fiber reinforced plastic (CFRP) fabric, a prepreg fabric, a woven cloth including a woven carbon fiber cloth, chopped fiber, a combination thereof , or other suitable fiber material.
[00091] Preferably, changing the direction of the laminated ray fill folds 110b (see FIG. 5), 110c (see FIG. 6), 110d (see FIG. 7) of the respective second portion 108b (see the FIG. 5), additional portion 108c (see FIG. 6), and / or additional portion 108d (see FIG. 7), minimizes a difference in CTE 136 (see FIG. 3) and interlaminar tensile stress 138 ( see FIG. 3) between the ray-fill laminate composite 70 (see FIGS. 4B, 5) and casing folds 84a, 84b (see FIGS. 4B, 5) adjacent to the ray-fill laminate composite 70 ( see Figures 4B, 5). Minimizing the difference in CTE 136 (see FIG. 3) and interlaminar tensile stress 138 (see FIG. 3) preferably eliminates delamination or results in a reduced delamination 140 (see FIG. 3) of the laminated composite of ray fill 70 (see FIG. 7). Such delamination may result from thermal stresses that occur during curing and thermal cycling stages of the composite structure 28 (see FIG. 4B) and / or composite assembly 26 (see FIG. 4B).
[00092] In another embodiment of the description, a method 150 of forming a ray-filled laminate composite 70 (see FIGS. 3, 4B, 5-7) for a composite structure 28 (see FIGS. 4A- 4B). FIG. 8 is an illustration of a flow chart of an example embodiment of method 150 of the description. The steps listed for method 150 can be performed in a different order than the one presented. Some steps can be performed simultaneously. Some steps can be optional or omitted. Steps other than those listed can be added.
[00093] The ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) can be formed of a composite material by any appropriate means including, but not limited to, pultrusion, extrusion, manual laying, laying automatic, or any other suitable forming process as described in more detail below. The ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) is formed in order to fill the volume of, and assume the shape and geometry of, the ray-fill region 72 (see FIGS. 3, 4A) to be completed. The configuration 74 (see FIGS. 4B, 5-7) of the ray-filled laminate composite 70 (see FIGS. 4B, 5-7) can preferably comprise a triangle-shaped configuration and can preferably have a generally cross section triangular. However, the ray-fill laminated composite 70 may have another appropriate cross-sectional shape and configuration.
[00094] As shown in FIG. 8, method 150 comprises step 152 of assembling a plurality of stacks of laminated radius fill folds 110a, 110b, 110c, 110d (see FIG. 3) cut to a desired width (see FIG. 3) 132 (see FIG. 3) and having a desired fold orientation 134 (see FIG. 3) to form a set of stacked folds 108 (see FIGS. 3, 4B, 5-7). The plurality of piles 110 (see FIG. 3) of laminated radius fill folds 110a, 110b, 110c, 110d (see FIG. 3) may be reduced in volume to compress or consolidate the plurality of stacks 110 (see FIG. 3) in order to remove voids, such as air or other gases, that can be trapped between the folds of the plurality of batteries 110 (see FIG. 3).
[00095] As shown in FIG. 8, method 150 further comprises step 154 of laying a first portion 108a (see FIGS. 3, 4B, 5-7) of the stacked fold assembly 108 (see FIGS. 3, 4B, 5-7) on a forming apparatus 128 (see FIG. 3). The forming apparatus 128 (see FIG. 3) may comprise a forming tool, a mold, a mandrel, a laying machine platform, an automated fiber laying machine (AFP), or other suitable forming apparatus. The laying of the plurality of batteries 110 (see FIG. 3) on the forming apparatus 128 (see FIG. 3) can be conducted via a manual process or via an automatic process, with a known apparatus or laying machine.
[00096] The first portion 108a (see FIG. 3) of the stacked fold assembly 108 (see FIG. 3) can comprise a three or four fold stack with preferably at least one fold having a zero degree fold orientation (0 °) and the other folds having a fold orientation of +50 degrees / -50 degrees or other desired fold orientation 134 (see FIG. 3). If an automatic laying process is used to form the stacked fold set 108 (see FIG. 3), the rolled radius fill folds 110a (see FIG. 4B) of the first portion 108a (see FIG. 3) they can be fitted with single folds in any desired fold orientation 134 (see FIG. 3).
[00097] The plurality of stacks 110 (see FIGS. 3, 4B, 5-7) can be cut into strips from a fold load with widths ranging from large widths to small widths to conform at a radial orientation 114 (see FIGS. 5-7) of the ray-filled laminate composite 70 (see FIGS. 5-7). The plurality of batteries 110 (see FIGS. 3, 4B, 5-7) can be cut using a known cutting device and a known cutting process, such as an ultrasonic cutting device and ultrasonic cutting process, a cutting device fabric cutting and fabric cutting process, a laser cutting device and laser cutting process, or other appropriate cutting device and cutting process.
[00098] The plurality of batteries 110 (see FIGS. 3, 4B, 5-7) can then be assembled, such as, for example, starting with the largest pile and proceeding to a final pile on the one or more elements geometrically shaped fillers 100 (see FIGS. 4B, 5-7) to form configuration 74 (see FIGS. 4B, 5-7) of the radius fill laminate composite 70 (see FIGS. 4B, 5-7 ).
[00099] As shown in FIG. 8, method 150 further comprises step 156 of positioning a geometrically shaped filling element 100 (see FIGS. 3, 4B, 5-7), for example, at a desired location 120 (see FIG. 5) on the first portion 108a (see FIG. 5) of the stacked fold assembly 108 (see FIG. 5), at a desired location 124 (see FIG. 6) on the second portion 108b (see FIG. 6) of the assembly stacked folds 108 (see FIG. 6), and / or at a desired location 126 (see FIG. 7) on the second portion 108b (see FIG. 7) of stacked folds 108 (see FIG. 7). Preferably, the desired location 120 (see FIG. 5) is a central location 120a or substantially central location (see FIG. 5) on the first portion 108a (see FIG. 5). However, other suitable locations can also be used. Preferably, the desired location 124 and the desired location 126 are also central locations or substantially central locations. Preferably, one or more geometrically shaped filling elements 100 (see FIGS. 3, 4B, 5-7) are positioned in the upper portion, such as half of the upper portion or third part of the upper portion, of the laminate filling composite of radii 70 (see FIGS. 4B, 5-7).
[000100] Method 150 may further comprise, before step 156 of positioning the geometrically shaped filling element 100 (see FIG. 5) at the desired location 120 (see FIG. 5), the step of shaping the filling element geometrically shaped 100 (see FIGS. 3, 4B, 5-7) from a material comprising a plurality of unidirectional fibers 101 (see FIG. 3), a unidirectional fiber tape, a pre-impregnated unidirectional tape, a unidirectional composite tow, a split unidirectional tape, a carbon fiber reinforced plastic (CFRP) tape, a carbon fiber reinforced plastic (CFRP) fabric, a pre-impregnated fabric, a woven cloth including a cloth woven carbon fibers, chopped fiber, a combination thereof, or other suitable composite material.
[000101] Method 150 may further comprise, before step 156 of positioning the geometrically shaped filling element 100 (see FIGS. 3, 4B, 5-7) in the desired location 120 (see FIG. 5), the step to further shape the geometrically shaped filling element 100 (see FIGS. 3, 4B, 5-7) into a geometric shape 102 (see FIGS. 3, 4B, 5-7). The geometric shape 102 (see FIGS. 3, 4B, 5-7) can comprise one of a triangle shape 102a (see FIGS. 4B, 5), a triangle shape with curved vertices 102b (see FIG. 6 ), an arrowhead shape 102c (see FIG. 7), a triangle shape with removed vertices (not shown), a triangle shape with one or more curved sides (not shown), a radius fill shape (not shown), a semicircle shape (not shown), or other appropriate geometric shape.
[000102] Method 150 (see FIG. 8) can further comprise, prior to step 156 of positioning the geometrically shaped filling element 100 (see FIG. 5) at the desired location 120 (see FIG. 5), the step of manufacturing the geometrically shaped filling element 100 (see FIG. 3). In one embodiment, the geometrically shaped filling element 100 (see FIG. 3) can be manufactured with a known pultrusion process using a known pultrusion apparatus 130 (see FIG. 3). The known pultrusion process using the known pultrusion apparatus 130 (see FIG. 3) can be used to assemble a desired amount of unidirectional fibers 101 (see FIG. 3) having a zero degree (0o) fold orientation, such as in the form of unidirectional composite tow or split tape, for example, 0.31 cm (1/8 inch) wide, and to pull them through a heated matrix of a desired shape. The pultrusion process creates a continuous, consolidated composite profile of a geometrically shaped filling element 100 (see FIG. 3), comprised of pultruded unidirectional fibers 101a (see FIG. 3). The geometrically shaped filler element 100 (see FIG. 3) that has been pultruded can be used to make a dragging tool surface to rest on the laminated radius filler folds 110b, 110c, 110d (see FIG 3). Alternatively, the geometrically shaped filling element 100 (see FIG. 3) can be manufactured with another suitable method, for example, with chopped fiber and a mold.
[000103] As shown in FIG. 8, method 150 further comprises step 158 of laying a second portion 108b (see FIGS. 3, 4B, 5-7) of the stacked fold assembly 108 (see FIGS. 3, 4B, 5-7) on the geometrically shaped filling element 100 (see FIGS. 3, 4B, 5-7) and the first portion 108a (see FIGS. 3, 4B, 5-7) of the stacked fold set 108 (see FIGS. 3, 4B, 5-7) to form a ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7). As shown in FIG. 5, the geometrically shaped filling element 100 preferably deforms the second portion 108b of the stacked fold assembly 108, so that the rolled radius fill folds 110b of the second portion 108b change direction and have a direction component 116 comprising the component horizontal 118a and vertical component 118b.
[000104] As shown in FIG. 8, method 150 comprises another additional step 160 of positioning one or more additional geometrically shaped filling elements, 100b (see FIG. 6), 100c (see FIG. 7), at a desired location 124 (see FIG. 6) or a desired location 126 (see FIG. 7), respectively, in each of one or more of the additional portion 108c (see FIG. 6) and / or the additional portion 108d (see FIG. 7), respectively, from the stacked fold set 108 (see FIG. 5). Each of the one or more additional geometrically shaped filling elements, 100b (see FIG. 6), 100c (see FIG. 7), can further deform one or more respective additional portions 108c (see FIG. 6), 108d (see FIG. 7), respectively, of the stacked fold set 108 (see FIG. 6) stacked on the respective one or more additional geometrically shaped filling elements, 100b (see FIG. 6), 100c ( see FIG. 7).
[000105] As shown in FIG. 8, method 150 comprises another additional step 162 of positioning a point member 104 (see FIGS. 5, 6) on an upper portion 122 (see FIGS. 5, 6) of the stacked fold assembly 108 (see FIGS. 5, 6), such as, for example, the upper portion 122 (see FIG. 5) of the second portion 108b (see FIG. 5) of the stacked fold assembly 108 (see FIG. 5), or the upper portion 122 (see FIG. 6) of the additional portion 108c (see FIG. 6) of the stacked fold assembly 108 (see FIG. 6). The tip element 104 (see FIGS. 5, 6) preferably comprises a plurality of unidirectional fibers 101 (see FIG. 3), a unidirectional fiber tape, a pre-impregnated unidirectional tape, a unidirectional composite tow, a unidirectional split tape, carbon fiber reinforced plastic (CFRP) tape, carbon fiber reinforced plastic (CFRP) fabric, prepreg fabric, woven cloth including woven carbon fiber cloth, fiber chopped, a combination thereof, or other appropriate fiber material.
[000106] In one embodiment, the tip element 104 (see FIGS. 5, 6) can be manufactured with a known pultrusion process using a known pultrusion apparatus 130 (see FIG. 3). The known pultrusion process using the known pultrusion apparatus 130 (see FIG. 3) can be used to assemble a desired amount of unidirectional fibers 101 (see FIG. 3) having a zero degree (0o) fold orientation, such as in the form of unidirectional composite tow or split tape, for example, 0.31 cm (1/8 inch) wide, and to pull them through a heated matrix of a desired shape. The pultrusion process creates a continuous, consolidated composite profile of a tip element 104 (see FIGS. 5, 6) comprised of pultruded unidirectional fibers 101a (see FIG. 3). Alternatively, the tip element 104 (see FIGS. 5, 6) can be manufactured with another suitable method, for example, with chopped fiber and a mold.
[000107] Once the point element 104 (see FIGS. 5, 6) is manufactured, it can be positioned on an upper portion 122 (see FIGS. 5, 6) of the stacked fold assembly 108 (see 5, 6), such as, for example, the upper portion 122 (see FIG. 5) of the second portion 108b (see FIG. 5) of the stacked fold assembly 108 (see FIG. 5), or the upper portion 122 (see FIG. 6) of the additional portion 108c (see FIG. 6) of the stacked fold assembly 108 (see FIG. 6), depending on how any geometrically shaped filling elements 100 (see FIGS) 5, 6) are positioned in the ray-fill laminate composite 70 (see FIGS. 5, 6).
[000108] As shown in FIG. 8, method 150 further comprises step 164 of assembling or installing the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) in a ray-fill region 72 (see FIGS. 3, 4A-4B) of a composite structure 28 (see FIGS. 3, 4A). The step 164 of assembling the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) can further comprise installing the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7 ) with a plurality of housing folds 84a, 84b, 92a (see FIG. 4B) positioned adjacent the radius fill region 72 (see FIG. 4B).
[000109] As shown in FIG. 8, method 150 may comprise another additional step 166 of curing the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) with a plurality of casing folds 84a, 84b, 92a (see FIG 4B) positioned adjacent to the radius fill region 72 (see FIG. 4B), resulting in the elimination of delamination or reduced delamination 140 (see FIG. 3) in the radius fill laminate composite 70 (see FIGS. 3, 4B, 5-7). The ray-filled laminate composite 70 (see FIGS. 3, 4B, 5-7) and the casing folds 84a, 84b, 92a (see FIG. 4B) of the composite structure 28 (see FIG. 4B) are preferably cured together under appropriate heat and pressure. The composite structure 28 can be further assembled to form a composite assembly 26.
[000110] The curing step 166 can optionally comprise placing the formed ray-filled laminate composite 70 (see FIGS. 3, 4B, 5-7) in a full length matrix having a desired radius and desired shape and compressing the formed ray-filled laminated composite 70 (see FIGS. 3, 4B, 5-7) in order to consolidate the ray-filled laminated composite 70 (see FIGS. 3, 4B, 5-7). Alternatively, consolidation of the formed ray-filled laminated composite 70 (see FIGS. 3, 4B, 5-7) in a matrix is not conducted.
[000111] Curing may comprise a known curing process, such as an autoclave curing process, a vacuum bag curing process, a combination of autoclave and vacuum bag curing processes, or other appropriate curing process . Curing can preferably take place at a high temperature and high pressure, as required by the material specifications, to effectively cure the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) and the composite structure 28 (see FIGS. 3, 4B) and / or composite assembly 26 (see FIGS. 3, 4B). During curing, the composite material of the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) hardens, and preferably maintains the shape of the ray-fill region 72 within the composite structure 28 and / or composite assembly 26. Composite structure 28 can be assembled in the form of composite assembly 26 and can be cured, such as in an autoclave under a pressure bag process, or other suitable apparatus or process, as is known in the art.
[000112] In another embodiment, the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) can be cured prior to assembly or installation within the ray-fill region 72 (see FIG. 4A ) of composite structure 28 (see FIG. 4A) and / or composite assembly 26 (see FIG. 4B), and cured ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) it can be glued or glued within the radius fill region 72 of a composite structure 28 and / or composite assembly 26, cured or uncured, via adhesive bonding, curing, secondary bonding, or another known bonding or bonding process. The gluing process can take place at a high temperature and high pressure, as required by the specifications of each material, to effectively glue or glue the cured ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) within the radius fill region 72 of a composite structure 28 and / or composite assembly 26, cured or uncured. For example, composite structure 28 (see FIG. 4B) comprising ray-filled laminate composite 70 (see FIG. 4B) and casing folds 84a, 84b, 92a (see FIG. 4B) can be separately cured and then can be glued to a fully cured covering panel 96 (see FIG. 4B) to form a composite assembly 26 (see FIG. 4B) suitable for use, for example, on wings 18 (see Figure 1) of an aircraft 10 (see Figure 1).
[000113] As will be appreciated by those skilled in the art, the incorporation of the ray-fill composite laminate 70 (see FIGS. 3, 4B, 5-7), as in the form of the ray-fill composite laminate 70a (see Figures 3, 4B, 5), ray-fill laminate composite 70b (see FIG. 6), or ray-fill laminate composite 70c (see FIG. 7), formed by modalities of the exposed method 150 (see Figure 8), in the form of composite structures 28 (see Figures 1, 4A), for example, wings 18 (see Figure 1) of an aircraft 10 (see Figure 1), results in a number substantial benefits. The described modalities of the laminated ray-fill composite 70 (see FIGS. 3, 4B, 5-7) and method 150 (see FIG. 8) use one or more geometrically shaped filling elements 100 (see FIGS. 3 , 4B, 5-7) to minimize the difference in thermal expansion coefficient (CTE) 136 (see FIG. 3) and interlaminar tensile stress 138 (see FIG. 3). This can be minimized by changing the direction of the laminated ray fill folds 110b (see FIG. 5), 110c (see FIG. 6), and / or HOd (see FIG. 7) of the respective second portion 108b ( see FIG. 5), additional portion 108c (see FIG. 6), and additional portion 108d (see FIG. 7), so that they have a steering component 116 (see FIG. 3) comprising the component horizontal 118a (see FIG. 3) and vertical component 118b (see FIG. 3). The improved minimization of the difference in CTE 136 (see FIG. 3) and interlaminar tensile stress 138 (see FIG. 3) can be optimized by changing the size and shape of each geometrically shaped filling element 100 (see FIGS. 3, 4B, 5-7) and the location of each geometrically shaped filling element 100 (see FIGS. 3, 4B, 5-7) within the ray-filled laminate composite 70 (see FIGS. 3, 4B, 5-7).
[000114] In addition, the described modalities of the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) and method 150 (see FIG. 8) provide the solution to the occurrence of delamination during the curing and thermal cycling stages of manufacturing certain laminated composite ray fillers, for example, certain laminated composite ray fillers, on aircraft stringers, while still allowing the use of laminated, composite ray fillings, which can have advantages in various applications over other types of radius fills. The use of one or more geometrically shaped filling elements 100 (see FIGS. 3, 4B, 5-7) in the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) can eliminate or reduce delamination in the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7). Such delamination can result from thermal stresses that occur during the curing and thermal cycling stages of manufacture. The improved design can reduce the interlaminar tensile stress 138 (see FIG. 3) in the ray-filled laminate composite 70 (see FIGS. 3, 4B, 5-7). In turn, a reduction in residual interlaminar tensile stress 138 (see FIG. 3) can also improve an extraction capacity or capacity of the ray-fill composite laminate 70 (see FIGS. 3, 4B, 5-7) . By reducing residual interlaminar tensile stress 138 (see FIG. 3) in the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7), the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) may be better able to manipulate fills transmitted to the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7). In addition, laminated radius fill folds 110b, 110c, 110d (see FIG. 3) that can be deformed by one or more geometrically shaped fill elements 100 (see FIGS. 3, 4B, 5-7) be bent out of the plane with the pull-out fill and can thus react to the pull-out fill.
[000115] Furthermore, the described modalities of the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) and method 150 (see FIG. 8) provide a plurality of stacks 110 (see FIG 3) laminated radius fill folds 110a, 110b, 110c, 110d (see FIG. 3) that can be configured to have any desired fold orientation, as opposed to requiring only the use of folds with a fold orientation zero degree (0o). In addition, preferably, the stacked fold assembly 108 (see FIGS. 3, 4B, 5-7) on the top portion of the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7), where delamination or crack formation typically begins, can be deformed or shaped by one or more geometrically shaped filling elements 100 (see FIGS. 3, 4B, 5-7) to bend over to have a steering component comprising the horizontal direction 118a (see FIGS. 5-7) and the vertical direction 118b (see FIGS. 5-7), so as to substantially coincide with the vertical direction 118b (see FIG. 4B) of the housing folds 84a, 84b (see FIG. 4B) adjacent to the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7). By changing the direction of the stacked fold set 108 (see FIGS. 3, 4B, 5-7) on the top portion of the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) to align more closely with the direction of the casing folds 84a, 84b (see FIG. 4B) adjacent to the radius filler laminate 70 (see FIGS. 3, 4B, 5-7), the difference in CTE 136 ( see FIG. 3) of the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) and of the casing folds 84a, 84b (see FIG. 4B) adjacent to the ray-fill laminate composite 70 (see FIGS. 3, 4B, 5-7) can be minimized.
[000116] Furthermore, the described modalities of the laminated ray-filling composite 70 (see FIGS. 3, 4B, 5-7) and method 150 (see FIG. 8) can provide a geometrically shaped filling element 100 (see FIG. 3) which was pultruded via a pultrusion process using a pultrusion apparatus 130 (see FIG. 3) and which is composed of pultruded unidirectional fibers 101a (see FIG. 3). Such a geometrically shaped filler element 100 (see FIG. 3) preferably has a geometric shape 102 (see FIG. 4B) in the form of a triangle shape 102a (see FIG. 4B) to create a drag tool surface away to seat the rolled radius fill folds 110b, 110c, 110d (see FIG. 3) above.
[000117] Many modifications and other modalities of the description will come to mind for a person specialized in the technique to which this description belongs, having the benefit of the teachings presented in the previous descriptions and in the associated drawings. The modalities described here are intended to be illustrative and are not intended to be limiting or exhaustive. Although specific terms are used here, they are used only in a generic and descriptive sense and not for purposes of limitation.

权利要求:
Claims (14)
[0001]
1. Ray-fill laminate composite (70) for a composite structure (28), characterized by the fact that it comprises: a set of stacked folds (108) comprising a plurality of stacks (110) of laminated ray-fill folds cut in a desired width (132) and having a desired fold orientation (134); and, a geometrically shaped filling element (100) positioned in a desired location on a first portion of the stacked folding set (108), the geometrically shaped filling element (100) deforming a second portion of the stacked folding set (108) , stacked on the geometrically shaped filling element (100), so that the rolled radius fill folds of the second portion of the stacked fold set (108) change direction and have a direction component comprising a horizontal direction and a direction vertical, the ray-fill laminate composite having a shape corresponding to a ray-fill region of the composite structure.
[0002]
A ray-fill laminate composite according to claim 1, characterized in that it additionally comprises a point element positioned on an upper portion of the stacked fold assembly (108), the point element comprising a plurality of unidirectional fibers, a unidirectional fiber tape, a prepreg unidirectional tape, a unidirectional composite tow, a split unidirectional tape, a carbon fiber reinforced plastic (CFRP) tape, a carbon fiber reinforced plastic (CFRP) fabric, a pre-impregnated fabric, a woven cloth including a woven carbon fiber cloth, chopped fiber, or a combination thereof.
[0003]
3. Ray-filled laminated composite according to claim 1 or 2, characterized by the fact that it additionally comprises one or more additional geometrically shaped (100) filling elements, each positioned in a desired location on one or more additional portions of the set of stacked folds (108), and each of one or more additional geometrically shaped filling elements (100), further deforming one or more respective additional portions of the stacked fold set (108) stacked on the respective one or more elements of geometrically shaped filling (100).
[0004]
4. Ray-filled laminated composite according to any one of claims 1 to 3, characterized in that the geometrically shaped filling element (100) comprises a plurality of unidirectional fibers, a unidirectional fiber tape, a unidirectional pre-tape -impregnated, unidirectional composite tow, split unidirectional tape, carbon fiber reinforced plastic (CFRP) tape, carbon fiber reinforced plastic (CFRP) fabric, pre-impregnated fabric, woven fabric including a woven carbon fiber cloth, chopped fiber, or a combination thereof.
[0005]
A ray-fill laminate composite according to any one of claims 1 to 4, characterized by the fact that the geometrically shaped filling element (100) is composed of unidirectional pultruded fibers having a zero degree (0o) bending orientation.
[0006]
6. Laminated ray-filling composite according to any one of claims 1 to 5, characterized by the fact that the geometrically shaped filling element (100) has a geometric shape comprising one of a triangle shape, a triangle shape with vertices curved, an arrowhead shape, a triangle shape with removed vertices, a triangle shape with one or more curved sides, a radius fill shape, and a semicircle shape.
[0007]
7. Laminated ray-fill composite according to any one of claims 1 to 6, characterized by the fact that the change in direction of the laminated ray-fill folds of the second portion minimizes a difference in the thermal expansion coefficient (CTE) and tension of interlaminar traction between the ray-fill laminate composite and a plurality of wrapping folds adjacent to the ray-fill laminate composite.
[0008]
Ray-filled laminate composite according to any one of claims 1 to 7, characterized in that the desired location on the first portion of the stacked fold assembly (108) is a central location.
[0009]
9. Method (150) for forming a laminated ray-filling composite (70) for a composite structure (28), the method characterized by the fact that it comprises the steps of: installing a plurality of stacks (110) of filling folds rolled radii cut to a desired width and having a desired fold orientation to form a stacked fold set (108); laying a first portion of the stacked fold assembly (108) on a forming apparatus; positioning a geometrically shaped filling element (100) in a desired location on the first portion of the stacked fold set (108); laying a second portion of the stacked fold assembly (108) on the geometrically shaped filling element (100) and the first portion to form a ray-filled laminate composite, the geometrically shaped filling element (100) deforming the second portion, so that the laminated radius fill folds of the second portion change direction and have a direction component comprising a horizontal direction and a vertical direction; and, assemble the ray-fill laminate composite (70) in a ray-fill region of a composite structure (28).
[0010]
Method according to claim 9, characterized in that it comprises, before the assembly step of the ray-filled laminate composite in the ray-filling region of the composite structure, the step of positioning one or more shaped filling elements additional geometrically (100) at a desired location in each of one or more additional portions of the stacked fold set (108), each of the one or more additional geometrically shaped fill elements (100) further deforming one or more respective additional portions of the set of stacked folds (108) stacked on the respective one or more geometrically shaped filling elements (100).
[0011]
Method according to claim 9 or 10, characterized in that it additionally comprises, before the assembly step of the ray-filled laminate composite in the radius-filling region of the composite structure, the step of positioning a point element over an upper portion of the stacked fold assembly (108), the tip element comprising a plurality of unidirectional fibers, a unidirectional fiber tape, a pre-impregnated unidirectional tape, a unidirectional composite tow, a divided unidirectional tape, a unidirectional tape carbon fiber reinforced plastic (CFRP), a carbon fiber reinforced plastic (CFRP) fabric, a prepreg fabric, a woven cloth including a woven carbon fiber cloth, chopped fiber, or a combination of themselves.
[0012]
Method according to any one of claims 9 all, characterized by the fact that it further comprises, after the assembly step of the ray-filled laminate composite in the ray-fill region of the composite structure, the step of curing the laminated composite of ray filling with a plurality of casing folds positioned adjacent the ray filling region, resulting in the elimination of delamination or reduced delamination in the ray-filled laminate composite.
[0013]
Method according to any one of claims 9 to 12, characterized in that it further comprises, before the step of positioning the geometrically shaped filling element (100) in the desired location, the step of shaping the geometrically shaped filling element ( 100) from a material comprising a plurality of unidirectional fibers, a unidirectional fiber tape, a pre-impregnated unidirectional tape, a unidirectional composite tow, a divided unidirectional tape, a carbon fiber reinforced plastic tape (CFRP) , a carbon fiber reinforced plastic (CFRP) fabric, a pre-impregnated fabric, a woven cloth including a woven carbon fiber cloth, chopped fiber, or a combination thereof, and further conform the shaped filler element geometrically (100) in a geometric shape comprising one of a triangle shape, a triangle shape with curved vertices, u m arrowhead shape, a triangle shape with removed vertices, a triangle shape with one or more curved sides, a radius fill shape, and a semicircle shape.
[0014]
Method according to any one of claims 9 to 13, characterized in that it further comprises, before the step of positioning the geometrically shaped filling element (100) in the desired location, the step of pulsing of unidirectional fibers having an orientation zero degree bending (0o) via a pultrusion process to form the geometrically shaped filling element (100).

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法律状态:
2016-09-27| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|

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2018-02-27| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|

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2020-03-24| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-07-14| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-08-04| 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 27/08/2014, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US14/074692|2013-11-07|

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US14/074,692|US9359060B2|2013-11-07|2013-11-07|Laminated composite radius filler with geometric shaped filler element and method of forming the same|

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