METHOD OF FORMING A RAY FILL

专利摘要:
method of forming a ray filler, and, ray filler. radius fillers (390) for composite structures (30), composite structures (30) which include radius fillings (390), and systems (100) and methods (400) for forming them are exposed here. methods (400) include determining a cross-sectional shape of an elongated void space (38), which extends within a transition region (40) which is defined by a plurality of veneers (48) of composite material (31 ), and determine a material ownership field in the transition region (40). the methods (400) further include forming the radius filler (390) by combining a plurality of lengths of composite tape (160) to define a radius filler (390) cross-sectional shape, which corresponds to the cross-sectional shape of the elongated void space (38), and orienting a plurality of lengths of reinforcing fiber (90) in each of the plurality of lengths of composite tape (160) based, at least in part, on the material property field of the region transition (420). radius fillers (390) include radius fillers (390) with selectively oriented reinforcement fibers (90). composite structures (30) include radius fillers (390).
公开号:BR102015005662B1
申请号:R102015005662-1
申请日:2015-03-13
公开日:2020-07-14
发明作者:Douglas A. Mccarville；Juan C. Guzman；Jordan Oliver Birkland；Ryan Shaw Tidwell；Robert L. Anderson
申请人:The Boeing Company；
IPC主号:

专利说明:

“METHOD OF FORMING A RAY FILLING” TECHNICAL FIELD
[001] This disclosure relates in general to digital fillers that can be used to fill empty spaces within composite structures and, more particularly, it concerns radius fillers with material properties that correspond to those material properties of surrounding composite structure and / or systems and methods of forming them. BACKGROUND OF THE TECHNIQUE
[002] Composite structures often include a laminate structure, in which sheets of a composite material, such as a pre-impregnated (or prepreg) material, can be curved, wrapped, and / or otherwise extended between a first plane, or surface, and a second plane, or surface. The finite thickness and / or mechanical stiffness of the sheets of composite material results in a finite curve, or finite radius of curvature, in a transition region between the first surface and the second surface; and, in some geometries, this finite radius of curvature results in an empty space, or cavity, between adjacent sheets of composite material.
[003] This empty space can be filled with, or otherwise occupied by, a filling material, such as a radius filler. The radius filler can be configured to provide mechanical support for those sheets of composite material that are close to it and / or to decrease the potential for distortion of those sheets of composite material, while the composite structure is being cured. Although the presence of the radius filler can provide a variety of benefits to the composite structure, differences between geometry, cross-sectional shape, and / or material property of the radius filler, when compared to a geometry, cross-sectional shape, and / or material property of the composite material defining that void, can distort the composite structure and / or the radius fill during formation and / or curing of the composite structure. Thus, it might be desirable to closely match the shape of the radius filler to a shape, or to a desired shape, of the void. In addition, it might also be desirable to combine the material properties of the radius filler with those of the composite material sheets and / or those of the resulting composite structure.
[004] Traditional ray fillers often use a single length of composite material that can be pleated at a number of locations to form an accordion shape, and then molded into a desired final shape. Alternatively, traditional radius fillers may use a plurality of lengths of composite material that are stacked on top of each other to form a plurality of parallel planes of composite material. Neither of these approaches allows for tight control of the shape and / or material properties of the radius filler, let alone combining the shape and / or material properties with those of the surrounding structure above. Thus, there is a need for improved beam fillers for composite structures, as well as improved systems and methods for the manufacture of beam fillers. SUMMARY OF THE INVENTION
[005] Radius fillers for composite structures, the composite structures that include radius fillers, and the systems and methods of forming them are set out here. The methods include determining a cross-sectional shape of an elongated void space, which extends within a transition region that is defined by a plurality of composite material veneers, and determining a material property field of the transition region. The methods further include forming the radius filler by combining a plurality of lengths of composite tape to define a radius filler cross-section shape, which corresponds to the cross-sectional shape of the elongated void space, and to orient a plurality of lengths reinforcing fiber in each of the plurality of composite tape lengths based, at least in part, on the material ownership field of the transition region.
[006] In some embodiments, determining the cross-sectional shape of the elongated empty space includes modeling said composite structure and / or determining a desired cross-sectional shape for the elongated empty space. In some embodiments, determining the material ownership field of the transition region includes modeling at least a portion of the composite structure.
[007] In some embodiments, the guidance includes orienting in such a way that a material property field of the radius filler corresponds to the material property field of the transition region. In some embodiments, the guidance includes orienting in such a way that the material property field of the radius filler corresponds to the material property field of the transition region within a difference of boundary material property field.
[008] In some embodiments, that determination of the material property field of the transition region includes determining a two-dimensional and / or three-dimensional material property field of that transition region. In some embodiments, the material ownership field of the transition region includes a stiffness field of the transition region, a thermal expansion coefficient field of the transition region, and / or a stress field of the transition region.
[009] In some embodiments, that determination of the material property field of the transition region includes determining a principal stress region within the transition region and / or determining a principal stress direction within that principal stress region. In some embodiments, the orientation includes orienting in such a way that at least one of the plurality of composite tape lengths defines a respective fiber geometric axis direction that extends within a portion of that radius filler that is located within the region of principal stress and / or that extends at least substantially parallel to the principal stress direction.
[0010] In some embodiments, the methods additionally include determining the direction of the fiber geometric axis within each of the plurality of composite tape lengths based, at least in part, on the cross-sectional shape of the elongated empty space and / or in the material ownership field of the transition region. In some embodiments, the methods further include establishing a relative location of each of the plurality of composite tape lengths within the radius filler based, at least in part, on the cross-sectional shape of the elongated empty space and / or in the field ownership of material from the transition region.
[0011] In some embodiments, the combination includes combining so that a fiber geometric axis direction of each length of composite tape that defines an outer radius filler surface is oriented in a direction that is parallel to a longitudinal geometric axis of the ray filling. In some embodiments, the combination includes receiving the plurality of composite tape lengths in a plurality of first apertures of a forming die, pressing the plurality of composite tape lengths together within the forming matrix to form the radius filler, and removing the radius filling from a second opening of the forming matrix. In some embodiments, the methods also include positioning the radius filler within the composite structure.
[0012] Radius fillers include radius fillers with selectively oriented reinforcement fibers. The radius fillers include a plurality of lengths of composite tape and each of the plurality of lengths of composite tape includes a respective plurality of lengths of reinforcement fibers. The plurality of lengths of reinforcement fibers in each of the plurality of lengths of composite tape define a respective fiber geometric axis direction which is selected based on the material property field of the transition region.
[0013] In some embodiments, the material property field of the radius filler corresponds to the material property field of the transition region. In some embodiments, the material property field of the radius filler combines the material property field of the transition region into a difference in boundary material property field.
[0014] Composite structures include a plurality of composite material veneers, which converge into a transition region to define an elongated void space, and radius fillings. In some embodiments, composite structures include an aircraft and / or a portion of an aircraft. BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Figure 1 is a schematic representation of an illustrative, non-exclusive example of an aircraft, which may include one or more composite structures that can use lightning fillers in accordance with the present disclosure.
[0016] Figure 2 is a schematic representation of illustrative, non-exclusive examples of a composite structure in accordance with the present disclosure.
[0017] Figure 3 is a schematic cross-sectional view of a transition region of a composite structure that can include and / or use a radius filler according to the present disclosure.
[0018] Figure 4 is a schematic top view of a length of composite tape that can be used with the systems and methods according to the present disclosure.
[0019] Figure 5 is another schematic top view of a length of composite tape that can be used with the systems and methods according to the present disclosure.
[0020] Figure 6 is another schematic top view of a length of composite tape that can be used with the systems and methods according to the present disclosure.
[0021] Figure 7 is a cross-sectional view of a radius filler according to the present disclosure.
[0022] Figure 8 is a schematic representation of a system for forming a radius filler according to the present disclosure and / or fiber geometric axis directions for lengths of composite tape that can be combined in a matrix of conformation to produce a radius filler according to the present disclosure.
[0023] Figure 9 is a schematic representation of a conformation matrix according to the present disclosure.
[0024] Figure 10 is another schematic representation of the conformation matrix of figure 9.
[0025] Figure 11 is another schematic representation of the conformation matrix of figure 9.
[0026] Figure 12 is a flow chart representing the methods of forming a radius filler according to the present disclosure. MODE FOR CARRYING OUT THE INVENTION
[0027] Figures 1-12 provide examples of fillings of radius 390 of composite structures 30 which include fillings of radius 390, and / or of systems 100 and methods 400 of manufacturing the fillers of radius. Elements that serve a similar, or at least substantially similar, purpose are designated with the same numbers in each of Figures 1-12, and such elements may not be discussed in detail here with reference to each of Figures 1-12. Similarly, all elements may not be designated in each of figures 1-12, but the reference numbers associated with them can be used here for consistency purposes. Elements, components, and / or features that are discussed here with reference to one or more of Figures 1-12 may be included in, and / or used with, any of Figures 1-12, without departing from the scope of this disclosure .
[0028] In general, elements that are likely to be included in a given modality (that is, a particular modality) are illustrated in solid lines, while elements that are optional to a given modality are illustrated in dashed lines. However, elements that are shown in solid lines are not essential to all of the modalities, and an element shown in solid lines can be omitted from a particular modality without departing from the scope of the present disclosure.
[0029] Figure 1 is a schematic representation of an illustrative, non-exclusive example of an aircraft 20, which may include one or more composite structures 30. Composite structures 30 may include and / or use fillings of radius 390 according to this disclosure. Composite structures 30 can form any suitable portion of aircraft 20. As illustrative, non-exclusive examples, composite structures 30 can form any appropriate portion of a cockpit 21, a fuselage 22, wings 23, a tail 24, a vertical stabilizer 25 , horizontal stabilizers 26, control surfaces 27, and / or an interior 28 of the aircraft 20.
[0030] Similarly, composite structures 30 may include any suitable shape, an illustrative, non-exclusive example, of which is shown in figure 2. A composite structure of figure 2 includes a coating 32 and a plurality of continuous strips 34, each of which it can be formed of one or more sheets, veneers, and / or settlements 48 of composite material 31. The composite structures 30 may include a single coating 32, with a plurality of "hat" reinforcements 36 that are formed from from continuous strips 34. Alternatively, and as illustrated in dashed lines in figure 2, composite structures 30 may also include two linings 32, with continuous strips 34 extending between them.
[0031] Regardless of the specific construction of composite structures 30, coverings 32 and / or continuous strips 34 can define voids 38, which can also be referred to here as elongated voids 38, as voids 38, and / or as elongated voids 38. voids 38 can be defined within a transition region 40 between linings 32 and continuous strips 34 and / or in any suitable transition region 40 between a foreground, or surface, 42 and a background , or surface, 44 of the composite structure 30. The voids 38 may be filled with, or otherwise occupied by, a radius filler 390, which may extend therein; and a shape and / or one or more material properties of radius filler 390 can impact a shape and / or one or more material properties of composite structures 30.
[0032] Figure 3 is a schematic cross-sectional view of a transition region 40 of a composite structure 30 that can include and / or use fillings of radius 390 in accordance with the present disclosure. As shown in Figure 3, the transition region 40 can be defined by a first veneer 50 of composite material 31, a second veneer 52 of composite material 31, and a third veneer 54 of composite material 31. However, other transition regions 40 are also within the scope of the present disclosure, including transition regions 40 that are defined by less than three veneers of composite material 31, by more than three veneers of composite material 31, and / or by a plurality of stacked veneers and / or in layers of composite material 31.
[0033] In the illustrative, non-exclusive example of figure 3, the first veneer 50 and the second veneer 52 converge into the transition region 40 to define a first contact region 56 between them. Similarly, the second veneer 52 and the third veneer 54 converge into the transition region 40 to define a second contact region 58 between them. In addition, the third veneer 54 and the first veneer 50 converge into the transition region 40 to define a third contact region 60 between them. As illustrated, the first contact region 56, the second contact region 58, and the third contact region 60 end within and / or in an empty space 38 which is defined within the transition region 40.
[0034] As illustrated in dashed lines, a radius filler 390 can extend into void 38, can substantially and / or completely fill void 38, can be in contact with veneer 50, the second veneer 52, and / or the third veneer 54, can be adhered and / or operably attached to the first veneer 50, the second veneer 52, and / or the third veneer 54, and / or can form an interface 70 with the first veneer 50, the second veneer 52 , and / or the third veneer 54. The void 38 and / or the radius filler 390 may have and / or define any appropriate cross-sectional shape, illustrative, non-exclusive examples of which include a triangular section shape transverse cross-section, a wedge-shaped cross-sectional shape, and / or a transverse cross-sectional shape that defines a base and a plurality of converging angled sides.
[0035] The first veneer 50, the second veneer 52, and the third veneer 54 can generally be referred to here as veneers 48 of composite material 31 and may have, or define, one or more properties of transition region material 40. These Material properties can be governed by, and / or based on, an overall shape and / or geometry of the composite structure 30 and / or the transition region 40 and / or a composite construction material 30 and / or veneers 48 that define the transition region 40. The veneers 48 can be formed of a composite material 31 that includes a plurality of reinforcement fibers 90, which are coated, encapsulated, and / or covered with a resin material 92. Under these conditions , the properties of transition region material 40 can also be governed by, and / or based on, a relative proportion of reinforcement fibers 90 of a resin material 92 within the veneers 48, a reinforcement fiber composition 90, a comp resin material position 92, a reinforcement fiber material property 90, a resin material material property 92, and / or a relative orientation of reinforcement fibers 90 within the veneers 48.
[0036] Generally, the material properties of the composite structure 30 and / or the transition region 40 thereof may not be uniform, may not be isotropic, may be anisotropic, and / or may vary with location and / or direction within composite structure 30 and / or within transition region 40 thereof. As an illustrative, non-exclusive example, the material properties of transition region 40 may be different in the X direction, in the Y direction, and in the Z direction due to the various characteristics of veneers 48, which are discussed above.
[0037] This variation in material properties with direction within transition region 40 can be described, quantified, and / or represented by a material property field for transition region 40 and can be determined and / or measured from any appropriate way. As an illustrative, non-exclusive example, transition region 40 can be formed and / or constructed and its material properties can be measured to determine the material property field of transition region 40. As another illustrative example, we cannot unique, the transition region 40 can be modeled, such as through any appropriate mathematical modeling and / or finite element analysis, to establish, estimate, and / or determine the material property field of the transition region 40.
[0038] As discussed in more detail here, the radius filler 390 includes, can be formed from, and / or can be formed exclusively from a plurality of composite tape lengths 160. The plurality of composite tape lengths 160 may be in face-to-face contact, in direct face-to-face contact, in close contact with each other, and / or pressed against each other within the radius filler 390. Each of the plurality of lengths of composite tape 160 can include a plurality of reinforcement fiber lengths 90 and a resin material 92. As discussed in more detail here, the plurality of reinforcement fiber lengths 90 within a given length of composite tape 160 is generally oriented in a fiber orientation direction, which can also be referred to here as a fiber geometric axis direction and / or as a fiber geometric axis. In fillings of radius 390 in accordance with the present disclosure, the relative orientation of the various lengths of composite tape and / or the direction of the fiber geometric axis of a given length of composite tape can be selected based on the material property field of the transition region 40.
[0039] The plurality of composite tape lengths 160 may include any appropriate number of composite tape lengths 160. As illustrative, non-exclusive examples, the plurality of composite tape lengths 160 may include at least 2, at least 4, at least 6, at least 8, at least 10, at least 15, at least 20, at least 30, at least 40, at least 50, at least 60, or at least 80 lengths of composite tape 160. It is within the scope of this invention the fact that the number of lengths of composite tape 160 can vary along the length of the radius filler 390, as well as to account for variations in the cross-sectional area of the void 38.
[0040] The plurality of composite tape lengths 160 within the radius filler 390 can be oriented so that composite tape lengths 160 are not coplanar with each other. Additionally or alternatively, the plurality of composite tape lengths 160 can also be oriented so that at least one of the plurality of composite tape lengths is in direct physical contact with another length of composite tape, but does not coplanarize with the other length of tape composite.
[0041] As a more specific, but still illustrative, non-exclusive example, a first length of composite tape 160 can be oriented at an angle of inclination with respect to a second length (or the rest of the length) of composite tape 160. Additionally or alternatively, a third length of composite tape can be oriented at an angle of inclination with respect to the first and second lengths of composite tape. Illustrative, non-exclusive examples of the angle of inclination include angles of inclination of at least 5 degrees, at least 10 degrees, at least 15 degrees, at least 20 degrees, at least 25 degrees, at least 30 degrees, at least 35 degrees, at least 40 degrees, or at least 45 degrees. Additionally or alternatively, the angle of inclination can also be less than 90 degrees, less than 85 degrees, less than 80 degrees, less than 75 degrees, less than 70 degrees, less than 65 degrees, less than 60 degrees, less than 55 degrees , less than 50 degrees, or less than 40 degrees. The angle of inclination can be measured in a cross section of the radius filler 390 (ie, in the X-Y plane).
[0042] It is within the scope of the present invention that the radius filler 390 may be formed solely and / or exclusively of composite tape lengths 160. As illustrative, non-exclusive examples, the radius filler 390 may not include a resin material and / or separate thermoplastic resin material extending between, and / or separated from, the lengths of the plurality of composite tape lengths separated from one another.
[0043] As discussed in more detail here, the various lengths of composite tape 160 can be oriented together so that a material property field of radius filler 390 corresponds to the material property field of transition region 40. This may include the orientation of the various lengths of composite tape so that they define inclination angles that make the material property field of radius filler 390 match the material property field of transition region 40 and / or select the various lengths of composite tape so that they define respective fiber geometric axis directions, which cause the material property field of radius filler 390 to correspond to the material property field of the transition region 40.
[0044] It is within the scope of the present invention that the material property field of radius filler 390 may correspond to the material property field of transition region 40 in any appropriate manner. As an illustrative, non-exclusive example, the material property field of radius filler 390 can adapt the material property field of the transition region 40 to within a boundary material property field difference at interface 70 between the region transition 40 (or veneers 48 thereof) and the radius filler 390. As illustrative, non-exclusive examples, the difference in field of property of boundary material may be less than 50%, less than 40%, less than 30%, less than 20%, less than 15%, less than 10%, less than 5%, less than 2.5%, or less than 1% of the material property field of the transition region at interface 70.
[0045] When used here, the phrases, "material property field of transition region 40", "material property field of transition region", "material property field of radius filler 390", and / or “radius filler material property field” can refer to any appropriate mathematical description of the magnitude, orientation, and / or variation in one or more material properties with the location and / or direction within the transition region 40 and / or radius fill 390, respectively. It is within the scope of the present invention that material property fields (transition region 40 and / or radius filler 390) can be one-dimensional material property fields that describe one or more material properties ( transition region 40 and / or radius filler 390) in a single direction (such as X direction, Y direction, or Z direction, although this is not required). In addition or alternatively, material property fields can be multidimensional material property fields that describe one or more material properties in two directions, in three directions, or in more than three directions. As an illustrative, non-exclusive example, material property fields can have a first field value in a first direction that extends along the empty space 38 (that is, the Z direction), a second field value in a second direction that is perpendicular to the first direction (that is, one in the X direction and the Y direction), and a third field value in a third direction that is perpendicular to the first direction and the second direction (that is, the other direction X and Y direction). Material property fields can also describe one or more material properties in a plurality of discrete locations within transition region 40 and / or radius filler 390.
[0046] It is within the scope of the present invention that the material property field of radius filler 390 may correspond to the material property field of transition region 40 in any direction and / or appropriate directions, including the first direction, the second direction, the third direction, within a plane that is defined by the first direction and the second direction, within a plane that is defined by the second direction and the third direction, and / or in a plane that is defined by first and third directions. Additionally or alternatively, the material property field of radius filler 390 may correspond to the material property field of transition region 40 within interface 70 and / or in a plurality of discrete locations within interface region 70.
[0047] Material property fields can also be referred to here as material property tensors, scalar material property fields, vector material property fields, material property distributions, and / or material property gradients.
[0048] It is within the scope of the present invention that any appropriate material property field of transition region 40 can be determined. The given material property field of the transition region 40 can then be used to establish, estimate, quantify, and / or determine one or more forces that can be applied to the radius filler 390 per transition region 40, to establish and / or selecting the direction of fiber geometric axis within a given length of composite tape 160 of radius filler 390 (such as by selecting the angle of inclination from the plurality of lengths of composite tape), to establish and / or select the orientation relative to the plurality of composite tape lengths 160 of radius filler 390, and / or to establish and / or select a desired material property field of radius filler 390. Non-exclusive illustrative examples of material property fields of transition region 40 include a stiffness field of transition region 40, a thermal expansion coefficient field of transition region 40, a region of camp the deformation transition field 40, a deformation field of the transition region 40, and / or a resin contraction field of the transition region 40. Illustrative, non-exclusive examples of material property fields of radius filler 390 include a stiffness field of radius filler 390, a thermal expansion coefficient field of radius filler 390, a stress field of radius filler 390, a deformation field of radius filler 390, and / or a contraction field resin from the 390 radius filler.
[0049] The stiffness field of transition region 40 can describe any appropriate stiffness of transition region 40 at any appropriate location and / or any appropriate locations, in any appropriate direction, and / or in any appropriate combination of directions. The stiffness can be quantified by any appropriate parameter, illustrative, non-exclusive examples, of which include a transition region elasticity module, a transition region Young modulus, and / or a transition region stiffness module. Similarly, the stiffness field of radius filler 390 can describe any appropriate stiffness of radius filler 390 at any appropriate location and / or any appropriate locations, in any appropriate direction, and / or in any appropriate combination of directions.
[0050] The thermal expansion coefficient field of transition region 40 can describe thermally induced expansion and / or contraction of veneers 48 within transition region 40 at any appropriate location and / or any appropriate locations, in any appropriate direction, and / or in any appropriate combination of directions. As an illustrative, non-exclusive example, veneers 48 can expand and / or contract significantly during the formation and / or curing of the composite structure 30, and the thermal expansion coefficient field of the transition region can describe this expansion and / or contraction. Similarly, the thermal expansion coefficient field of radius filler 390 can describe any appropriate thermally induced expansion and / or contraction of composite tape lengths 160 within radius filler 390 at any appropriate location and / or any appropriate locations, at any appropriate direction, and / or in any appropriate combination of directions.
[0051] The stress field of the transition region 40 may describe a state of tension, or residual stress, of the veneers 48, within the transition region 40 at a given point in time and / or at any appropriate location and / or any appropriate locations, in any appropriate direction, and / or in any appropriate combination of directions. Such a state of tension can produce and / or generate movement (that is, deformation) and / or relaxation of the veneers 48 within the transition region 40, thus altering an empty space shape 38 and / or applying one or more forces to the radius filler 390. As an illustrative, non-exclusive example, and subsequent to formation, but before curing the composite structure 30, veneers 48 may contain stress residues, and these stress residues may relax during curing of the composite structure 30. This relaxation can produce the movement of the veneers 48, thus changing the shape of the empty space 38 and / or applying one or more forces to the radius filler 390. Similarly, the field tension of the radius filler 390 can describe a state of tension, or residual tension, of composite tape lengths 160 within radius filler 390 at a given point in time and / or at any appropriate location and / or any appropriate locations, in any appropriate direction, and / or in any er appropriate combination of directions.
[0052] When the material property field of that transition region 40 includes the stress field of the transition region 40, the stress field of the transition region 40 can define a principal, basilar, high, and / or highest 80, which can be tensioned in a principal, basilar, high, and / or highest tension direction 82. Under these conditions, at least one length of composite tape from the plurality of lengths of composite tape can be oriented in such a way such that a respective fiber geometric axis direction 162 of the plurality of reinforcement fibers 90 thereof is located and / or extends within the main stress region 80 and is, or extends, at least substantially parallel to the main stress direction 82. In addition or alternatively, the plurality of composite tape lengths can be oriented in such a way that a plane that passes through the radius filler 390 and is perpendicular to the principal stress direction 82 inter pick the plurality of reinforcement fiber lengths of at least one of the composite tape lengths. This can increase the crack resistance and / or separation of the radius filler 390 in the composite structure 30. Additionally or alternatively, the radius filler 390 can define an apex region 84 within a plane that is perpendicular to a longitudinal geometric axis of the void 38 (i.e., perpendicular to the Z axis and / or in the XY plane), and at least one length of composite tape from the plurality of lengths of composite tape can define a respective fiber geometric axis direction that is directed inward from apex region 84.
[0053] The principal stress direction may be measured and / or defined with any appropriate orientation within the transition region 40. As an illustrative, non-exclusive example, the principal stress direction may be measured and / or defined perpendicular to the geometric axis longitudinal of that empty space 38 (that is, perpendicular to the geometric axis Z and / or in the X-Y plane).
[0054] The deformation field of that transition region 40 can describe a state of deformation of veneers 48 within the transition region 40 at a given point in time and / or at any appropriate location and / or any appropriate locations, in any direction appropriate, and / or in any appropriate combination of directions. Such a deformed state can change and / or relax with time, changing the void shape 38 again and applying one or more forces to the radius filler 390. As an illustrative, non-exclusive example, curing the composite structure 30 can cause changes in the deformation state. As another illustrative, non-exclusive example, and during the operation and / or use of the composite structure 30, the deformation field can change and / or fluctuate, thus changing the shape of the empty space 38 and / or applying one or more forces to the radius filler 390. Similarly, the deformation field of the radius filler 390 may describe a deformation state of composite tape lengths 160 within the radius filler 390 at the given point in time and / or at any appropriate location and / or any appropriate locations, in any appropriate direction, and / or in any appropriate combination of directions.
[0055] The resin contraction field of the transition region 40 can describe changes in the volume of resin and / or the location within the transition region 40 at any appropriate point in time, such as during curing of the composite structure 30. These changes in the volume of resin and / or location may, again, produce changes in the shape of the void 38. In addition or alternatively, these changes in the volume of resin and / or location can also generate changes in the stiffness of the transition region 40 Similarly, the resin shrinkage field of radius filler 390 can describe changes in resin volume and / or location within the radius filler 390 at a given point in time.
[0056] Figures 4-6 are schematic top views of lengths of composite tape 160 that can be used with the systems and methods according to the present disclosure. As discussed, each length of composite tape 160 may include a plurality of reinforcement fibers 90 and a resin material 92. The resin material 92 may cover, wrap, and / or encapsulate reinforcement fibers 90. Illustrative, non-exclusive examples reinforcement fibers 90, include any suitable carbon, titanium, glass, and / or metal fiber. Illustrative, non-exclusive examples of resin material 92 include any suitable epoxy and / or polymeric material.
[0057] The lengths of composite tape 160 may have and / or define any appropriate length and / or width within the radius fillings 390 in accordance with the present disclosure. As illustrative, non-exclusive examples, at least a portion of the plurality of composite tape lengths 160 may have a length of at least 1 meter (m), at least 2 m, at least 3 m, at least 4 m, at least 5 m, at least 6 m, at least 7 m, at least 8 m, at least 9 m, at least 10 m, at least 15 m, and / or at least 20 m. Additionally or alternatively, the length can also be less than 50 m, less than 40 m, less than 30 m, less than 25 m, less than 20 m, less than 15 m, less than 10 m, and / or less than 5 m.
[0058] As additional, non-exclusive illustrative examples, at least a portion of the plurality of composite tape lengths 160 may have a width of at least 3 mm (mm), at least 4 mm, at least 5 mm, at least 6 mm , at least 7 mm, at least 8 mm, at least 9 mm, at least 10 mm, at least 11 mm, at least 12 mm, at least 14 mm, at least 16 mm, at least 18 mm, at least 20 mm , and / or at least 24 mm. Additionally or alternatively, the width can also be less than 50 mm, less than 45 mm, less than 40 mm, less than 35 mm, less than 30 mm, less than 25 mm, less than 20 mm, less than 18 mm, less at 16 mm, less than 14 mm, less than 12 mm, less than 10 mm, less than 8 mm, less than 6 mm, and / or less than 4 mm.
[0059] The plurality of composite tape lengths portion may include and / or be any appropriate portion, percentage, and / or fraction of the plurality of composite tape lengths. As illustrative, non-exclusive examples, the plurality of composite tape lengths portion may include at least one composite tape length, two composite tape lengths, three composite tape lengths, at least 25% of the plurality of composite tape lengths, at least 50% of the plurality of composite tape, at least 75% of the plurality of composite tape lengths, and / or 100% of the plurality of composite tape lengths.
[0060] As illustrated in figures 4-6, the reinforcement fibers 90 (or a longitudinal geometric axis of fibers 90) of a given length of composite tape 160 can be oriented, or generally oriented, along, and / or parallel a, a fiber geometric axis direction 162. The given composite tape length 160 can also define a longitudinal geometric axis 392, which can be at least substantially parallel to, and / or may be referred to herein as, a longitudinal geometric axis of radius filler 392 of radius filler 390 when lengths of composite tape 160 are positioned within radius filler 390. It is within the scope of the present invention that the fiber axis direction 162 can be parallel to the longitudinal axis 392 (as shown in figure 4) and / or oriented at a fiber angle 164 with respect to the longitudinal geometric axis 392 (as shown in figures 5-6). As discussed, the fiber angle can be selected based, at least in part, on the material ownership field of the transition region 40.
[0061] Illustrative, non-exclusive examples of fiber angle 164 include fiber angles of at least 5 degrees, at least 10 degrees, at least 15 degrees, at least 20 degrees, at least 25 degrees, at least 30 degrees, at least 35 degrees, at least 40 degrees, and / or at least 45 degrees. Additionally or alternatively, the fiber angle 164 may also be less than 85 degrees, less than 80 degrees, less than 75 degrees, less than 70 degrees, less than 65 degrees, less than 60 degrees, less than 55 degrees, less than 50 degrees, and / or less than 40 degrees.
[0062] As illustrated in dashed lines in figure 5, the reinforcement fibers 90 can also be oriented to form a two-dimensional arrangement within a given length of composite tape 160. Illustrative, non-exclusive examples of the two-dimensional arrangement include a mesh, a woven structure, cloth, and / or a random arrangement of reinforcement fibers 90. It is also within the scope of the present disclosure that reinforcement fibers 90 can form a three-dimensional arrangement within a given length of composite tape 160. Illustrative, non-exclusive examples of the three-dimensional arrangement include a mesh, a woven structure, a cloth, a random arrangement of reinforcement fibers, and / or two or more arrangements of two or more dimensions of reinforcement fibers that are stacked one on top of the other. another.
[0063] Figure 7 is a cross-sectional view of a radius filler 390 in accordance with the present disclosure. As discussed, radius filler 390 includes a plurality of composite tape lengths 160. As also discussed, at least a portion of the plurality of composite tape lengths 160 is oriented at an angle of inclination with respect to a remainder of the plurality of lengths composite tape 160 within radius filler 390.
[0064] Figure 7 illustrates a specific relative orientation for the lengths of composite tape 160 within the radius filler 390; nevertheless, other relative orientations are also within the scope of this disclosure, such as those relative orientations that can be selected based, at least in part, on a specific field of material properties of a given transition region 40, such as discussed here. Figure 7 also illustrates that, as discussed, transition region 40 can define a major stress region 80 that can include and / or define a major stress direction 82, and at least a portion of the plurality of composite tape lengths 160 it can be oriented so that a fiber geometry axis direction 162 of reinforcement fibers 90 extends at least substantially parallel to the main stress direction. Additionally or alternatively, and as also discussed, the radius filler 390 can define one or more apex regions 84, and at least a portion of the plurality of composite tape lengths can be oriented so that reinforcement fibers 90 thereof define a geometric fiber axis direction 162 which is directed inward and / or extends within apex region 84.
[0065] Figure 8 is a schematic representation of a system 100 for forming a radius filler 390 in accordance with the present disclosure. Figure 8 illustrates fiber geometric axis directions 162 for composite strip lengths 160 that can be combined in a forming matrix 306 to produce radius filler 390 in accordance with the present disclosure and / or inclination angles for composite strip lengths. 160 within radius fillers 390 in accordance with the present disclosure. In figure 8, a plurality of lengths of composite tape 160 can be provided for the forming matrix 306 according to the present disclosure. Forming matrix 306 can also be referred to herein as a radius filler matrix 306 and can be configured to receive the plurality of composite tape lengths 160 and to converge the plurality of composite tape lengths 160 within it to produce and / or generate the radius filler 390. Illustrative, non-exclusive examples of matrix formation 306 are illustrated in figures 9 to 11 and discussed here. Additional, non-exclusive illustrative examples of matrix forming 306 and / or systems 100, which include forming matrix 306 and / or that can be used to form radius filler 390 are set out in US Patent Application Publication No. 2014/0034236, whose full disclosure is hereby incorporated for reference.
[0066] As discussed, each length of composite tape 160 can include a plurality of reinforcement fibers 90 and a resin material 92. As also discussed, the plurality of reinforcement fibers 90 of a given length of composite tape 160 can be oriented at any appropriate fiber angle 164 with respect to a longitudinal geometric axis 392 thereof. The longitudinal axis 392 can also be referred to here as a radius filler longitudinal axis 392, since when composite tape lengths 160 are combined to form the radius filler 390. This is illustrated in more detail in figure 8 at 164, in which schematic cross-sectional views of various lengths of composite tape 160 including reinforcement fibers 90 are illustrated. As illustrated at 166, the fiber angle 164 can be zero degrees (i.e., the direction of the fiber geometric axis 162 can be parallel to the longitudinal geometric axis 392). Under these conditions, the fibers 90 may appear somewhat circular in cross-section and / or may define a relatively small cross-sectional area.
[0067] Additionally or alternatively, and as illustrated in 168, the fiber angle 164 can be a finite angle that is between 0 degrees and 90 degrees, such as 45 degrees (i.e., the fiber axis geometric direction 162 and the longitudinal geometric axis 392 can define a fiber angle 164 of 45 degrees between them). Under these conditions, fibers 90 may appear more oblong in cross section and / or may define a relatively larger cross section area.
[0068] Additionally or alternatively, and as illustrated in 170, the fiber angle 164 can be approximately 90 degrees (i.e., the direction of the fiber geometric axis 162 and the longitudinal geometric axis 392 can define a fiber angle 164 of 90 degrees between them). Under these conditions, fibers 90 may appear linear in cross section.
[0069] Figures 9 to 11 are schematic representations of a 306 conformation matrix in accordance with the present disclosure. The forming die 306 includes a die body 330 which defines a first side 332 and a second side 334. As illustrated in figures 9 and 10, the first side 332 defines a plurality of first openings 336 which are configured to receive the plurality of composite tape lengths 160 (as shown in figure 8). As illustrated in Figure 10, the plurality of first openings directs the plurality of lengths of composite tape 160 into a plurality of channels 340 which are defined within the matrix body 330. The plurality of channels 340 can converge to each other within of the die body 330 and can cause the plurality of composite tape lengths 160 to contact and / or press against each other within the die body 330 prior to the exit of the forming die 306 through a second opening 338 which is defined on the second side 334, as illustrated in figure 11.
[0070] Figure 12 is a flow chart representing methods 400 of forming a radius filler for a composite structure according to the present disclosure. A composite structure can include a plurality of composite material veneers that converge into a transition region to define an elongated void. The radius filler can be configured to extend within the elongated void space and / or to support a portion of the plurality of composite material veneers that define the elongated void space. Methods 400 may include modeling the radius filler at 410 and / or modeling the transition region at 420. Methods 400 include determining a cross-sectional shape of the elongated void space at 430 and determining a material property field of the region transition at 440. Methods 400 may further include determining a property of a plurality of lengths of composite tape, which sets the radius fill to 450 and / or the formation of a layered stack of composite tape to 460. Methods 400 further include forming the radius filler at 470 and may include positioning the radius filler within the composite structure at 480.
[0071] Modeling of lightning filler at 410 may include modeling, establishing, and / or determining any appropriate properties of lightning filler. As an illustrative, non-exclusive example, modeling at 410 may include modeling a material property field of the radius filler. Illustrative, non-exclusive examples of the radius filler material property field include a radius filler stiffness field, a radius filler thermal expansion coefficient field, a radius filler stress field, and / or a resin contraction field from the radius filler. It is within the scope of the present invention that the modeling in 410 may include modeling in any appropriate manner. As illustrative, non-exclusive examples, modeling at 410 may include mathematical modeling of ray fill and / or finite element analysis of ray fill.
[0072] The modeling of the transition region in 420 may include modeling, establishing, and / or determining any appropriate properties of the transition region. As an illustrative, non-exclusive example, modeling in 420 may include modeling the material property field of the transition region, such as to allow and / or facilitate determination in 440.
[0073] It is within the scope of the present disclosure that the modeling in 420 can include modeling any appropriate portion of the composite structure under any appropriate conditions. As illustrative, non-exclusive examples, modeling in 420 may include modeling the transition region, modeling the transition region cure, modeling the transition region during the operation of the composite structure, modeling the composite structure, modeling the composite structure healing , and / or model the composite structure during the operation of the composite structure.
[0074] Determination of the cross-sectional shape of the elongated void space at 430 may include determining the cross-sectional shape of the elongated void space in any appropriate manner. As illustrative, non-exclusive examples, the determination in 430 may include modeling the composite structure, the transition region, and / or the elongated empty space. As another illustrative, non-exclusive example, the determination at 430 may include measuring the elongated void. As yet another illustrative, non-exclusive example, the determination at 430 may include establishing and / or determining a desired cross-sectional shape of the elongated void.
[0075] Determining the material ownership field of the transition region in 440 may include determining any appropriate material ownership field of the transition region in any appropriate manner. As an illustrative, non-exclusive example, the determination in 440 may include modeling the composite structure, the transition region, and / or the elongated void space, such as through modeling in 420. As another illustrative, non-exclusive example, the 440 determination may include measuring the material ownership field of the transition region. As yet another illustrative, non-exclusive example, the determination at 440 may include establishing and / or determining a desired material property field in the transition region.
[0076] It is within the scope of the present invention that the determination at 440 may include determining any appropriate material property field of the transition region in any appropriate dimension, combination of dimensions, direction, and / or combination of directions. Illustrative, non-exclusive examples of the material property field of the transition region include a stiffness field of the transition region, a thermal expansion coefficient field of the transition region, a stress field of the transition region, and / or a resin contraction field from the transition region.
[0077] Determination at 440 may include determining a one-dimensional material property field from the transition region, determining a two-dimensional material property field from the transition region, and / or determining a three-dimensional material property field from the transition region . As a more specific, but still illustrative, non-exclusive example, the determination at 440 may include determining a first field value of the material property field of the transition region in a first direction that extends across the elongated empty space, determining a second field value of the material property field of the transition region in a second direction which is perpendicular to the first direction, and / or determine a third field value of the material property field of the transition region in a third direction which is perpendicular to the first direction and the second direction. As another more specific, but still illustrative, non-exclusive example, the determination at 440 may also include establishing an arrangement and / or grid of values for the material ownership field at various locations within the transition region.
[0078] Additionally or alternatively, determination at 440 may also include determining a principal stress region within the transition region and / or determining a principal stress direction within the principal stress region. The main stress region can include and / or be a portion of the transition region that has the maximum stress and / or that is greater than a limit stress value. The main stress direction can be a direction, or middle direction, through which the stress is applied within the main stress region.
[0079] Determining the property of the plurality of composite tape lengths at 450 may include determining and / or establishing any appropriate property of any appropriate portion of the plurality of composite tape lengths. The determination at 450 can be based on any appropriate criteria and can be performed with any appropriate sequence of methods 400, such as before training at 470.
[0080] As an illustrative, non-exclusive example, the determination at 450 may include determining and / or establishing a width of each of the plurality of composite tape lengths based, at least in part, on the cross-sectional shape of the space elongated void and / or in the material ownership field of the transition region. As another illustrative, non-exclusive example, the determination at 450 may include determining and / or establishing the thickness of each of the plurality of composite tape lengths based, at least in part, on the cross-sectional shape of the elongated empty space and / or in the material ownership field of the transition region.
[0081] As yet another illustrative, non-exclusive example, the determination at 450 may also include determining and / or establishing the fiber geometric axis direction within each of the plurality of composite tape lengths based, at least in part , in the cross-sectional shape of the elongated empty space and / or in the material property field of the transition region. As another illustrative, non-exclusive example, the determination at 450 may include determining and / or establishing a relative location of each of the plurality of composite tape lengths within the radius filler based, at least in part, on the cross-sectional shape section of the elongated empty space and / or in the material property field of the transition region.
[0082] Formation of the layered stack of composite tape at 460 may include forming any appropriate layered stack that includes two or more lengths of composite tape and may be carried out prior to formation at 470. As an illustrative, non-exclusive example, layered stack of composite tape can include a first length of composite tape that defines a first fiber geometry axis direction and a second composite ribbon length that defines a second fiber geometry axis direction that is different from the first geometric axis direction fiber. As a more specific, but still illustrative, non-exclusive example, the first fiber geometric axis direction can be at least substantially parallel to a longitudinal geometric axis of the composite tape length (i.e., the first fiber geometric axis direction can be be oriented at a zero degree fiber angle, as shown in figure 4), while the second fiber geometry axis direction can be at least substantially perpendicular to the longitudinal geometrical axis of the composite tape length (ie the second geometric axis of fiber can be oriented at a fiber angle of 90 degrees, as illustrated in figure 6). This may allow formation in 470 to be performed using a pultrusion process without shearing the second length of composite tape.
[0083] The formation of the lightning filler at 470 may include forming the lightning filler in any appropriate manner. As an illustrative, non-exclusive example, the formation at 470 may include combining, at 472, the plurality of lengths of composite tape to define a cross-sectional shape of the radius filler that corresponds to the cross-sectional shape of the elongated empty space . As another illustrative, non-exclusive example, the formation in 470 may also include guiding, in 474, the plurality of lengths of reinforcement fiber in each of the plurality of lengths of composite tape based, at least in part, on the property field. material from the transition region. Each of the plurality of composite tape lengths can include a respective plurality of reinforcement fiber lengths and a resin material, and the plurality of reinforcement fiber lengths in each of the plurality of composite tape lengths define a respective direction of geometric fiber axis.
[0084] The combination at 472 may include combining in any appropriate manner and may include combining so that an outer radius filler surface is defined by lengths of composite tape that have, or define, a fiber geometric axis direction that is parallel to a longitudinal geometric axis of the radius filler. As an illustrative, non-exclusive example, combination in 472 may include combining with a pultrusion process. According to another illustrative, non-exclusive example, the combination at 472 can also include combining with pressure forming process.
[0085] As a more specific, but still illustrative, non-exclusive example, the combination at 472 may include receiving the plurality of lengths of composite tape in a plurality of first openings on a first side of a forming die, pressing the plurality of lengths of composite tape against each other within the forming matrix to form the radius filler, and removing the radius filler from (a single) second opening on a second side of the forming matrix. Under these conditions, the combination at 472 can be a process at least substantially continuous, in which reception, pressing, and removal are carried out concurrently and / or simultaneously. The forming matrix can define a plurality of channels that span between the plurality of first openings and the second opening, and the orientation at 474 may include selecting a relative orientation from among the plurality of channels, such as by selecting the forming matrix and / or by selecting the configuration of the plurality of channels within the conformation matrix.
[0086] Guidance at 474 may include orienting so that the material property field of the radius filler corresponds to, and / or is based on, the material property field of the transition region. This may include orienting so that the material property field of the radius filler conjugates the material property field of the transition region into a difference of boundary material property field at an interface between the transition region and the ray filling. Illustrative, non-exclusive examples of the difference in field of ownership of boundary material are set out here.
[0087] When the determination in 440 includes determining the principal stress region and / or the principal stress direction, the guidance at 474 may further include orienting in such a way that at least one of the plurality of composite tape lengths defines the respective direction geometric fiber axis extending within a portion of the radius filler that is located within the main stress region and / or that is aligned at least substantially parallel to the main stress direction. Where methods 400 include modeling in 410 and / or modeling in 420, guidance in 474 may include guidance based, at least in part, on modeling in 410 and / or modeling in 420.
[0088] The positioning of the radius filler within the composite structure at 480 may include positioning and / or placing the radius filler within the composite structure. This may include positioning and / or placing so that the radius filler extends into the elongated void space and / or contacts the plurality of composite material veneers that define the elongated void space. It is within the scope of the present invention that, subsequent to positioning at 480, methods 400 may further include heating and / or curing the composite structure.
[0089] Illustrative, non-exclusive examples of the inventive material according to the present disclosure are described in the following enumerated paragraphs:
[0090] Al. A method of forming a radius filler for the composite structure, wherein the composite structure includes a plurality of veneers of composite material that converge into a transition region to define an elongated void space, and, in addition, wherein the radius filler is configured to extend into the elongated void space, the method comprising: determining a cross-sectional shape of the elongated void space; determine a material ownership field in the transition region; and forming the radius filler, wherein the formation includes: combining a plurality of lengths of composite tape to define a cross-sectional shape of the radius filler that corresponds to the cross-sectional shape of the elongated empty space, where each the plurality of lengths of composite tape includes a respective plurality of lengths of reinforcing fiber and a resin material, and yet each of the plurality of lengths of composite tape defines a direction of the fiber geometric axis; and guiding the plurality of reinforcement fiber lengths of each of the plurality of composite tape lengths based, at least in part, on the material ownership field of the transition region.
[0091] A2. The method according to paragraph A1, in which the determination of the cross-sectional shape of the elongated empty space includes at least one among modeling the composite structure and determining a desired cross-sectional shape for the elongated empty space.
[0092] A3. The method according to any of paragraphs A1-A2, in which the determination of the material property field of the transition region includes at least one among modeling the transition region, modeling the healing of the transition region, modeling the transition region during the operation of the composite structure, model the composite structure, model the healing of the composite structure, and model the composite structure during the operation of the composite structure.
[0093] A4. The method according to any of the paragraphs Al-A3, "> where the guidance includes orienting so that a material property field of the radius filler is at least one of: (i) corresponds to the material property field of the region and (ii) corresponds to the material property field of the transition region within a difference of the material property field boundary at an interface between the transition region and the radius fill.
[0094] A5. The method according to paragraph A4, in which the field difference of ownership of boundary material is less than 50%, less than 40%, less than 30%, less than 20%, less than 15%, less than 10% , less than 5%, less than 2.5%, or less than 1% of the material ownership field in the transition region.
[0095] A6. The method according to any of paragraphs A1-A5, in which the determination of the material property field of the transition region includes at least one among determining a two-dimensional material property field of the transition region and determining a property field of three-dimensional material from the transition region.
[0096] A7. The method according to any of paragraphs A1-A6, in which the material property field of the transition region has a first field value in a first direction that extends along the elongated empty space, a second field value in a second direction that is perpendicular to the first direction, and a third field value in a third direction that is perpendicular to the first direction and the second direction.
[0097] A8. The method according to paragraph A7, in which the determination of the material property field of the transition region includes determining at least two, and optionally all, of the first field value, the second field value, and the third field.
[0098] A9. The method according to any of paragraphs A7-A8, wherein determining the material property field of the transition region includes determining the second field value and the third field value.
[0099] A10. The method according to any of the paragraphs Al-A9, in which the material property field of the transition region includes a stiffness field of the transition region, and optionally in which a material property field of the radius filler includes a field of rigidity of the radius filler.
[00100] A1l. The method according to any of the paragraphs Al-A10, in which the material property field of the transition region includes a thermal expansion coefficient field of the transition region, and optionally in which a material property field of the transition region. lightning filler includes a thermal expansion coefficient field of the lightning filler.
[00101] A12. The method according to any of the Al-All paragraphs, in which the material property field of the transition region includes a stress field of the transition region, and optionally in which a material property field of the radius filler includes a beam filling voltage field.
[00102] Al3. The method according to any of paragraphs A-A12, wherein determining the material property field of the transition region includes determining a principal stress region within the transition region and determining a principal stress direction within the stress region main, and furthermore that the orientation includes orienting so that at least one of the plurality of composite tape lengths defines a respective fiber geometric axis direction that extends within a portion of the radius filler that is located within the region of main stress and at least substantially parallel to the main stress direction.
[00103] A14. The method according to any of the paragraphs Al - "> A13, in which the material property field of the transition region includes a resin contraction field of the transition region which corresponds to the contraction of resin material within the plurality of veneers of composite material during curing of the composite structure, and optionally wherein a material property field of the radius filler includes a resin contraction field of the radius filler which corresponds to the contraction of resin material within the radius filler during healing of the composite structure.
[00104] A15. The method according to any of the paragraphs Al-A14, in which the method also includes The modeling of the radius filler, and in which the guidance includes orienting based on the modeling.
[00105] A16. The method according to any of paragraphs Al-A15, in which, before combining, the method further includes determining the width of each of the plurality of composite tape lengths based, at least in part, on at least one of the cross-sectional shape of the elongated empty space and the material property field of the transition region.
[00106] A17. The method according to any of paragraphs Al-A16, in which, before combining, the method further includes determining the thickness of each of the plurality of composite tape lengths based, at least in part, on at least one of the cross-sectional shape of the elongated empty space and the material property field of the transition region.
[00107] Al8. The method according to any of the paragraphs A-A17, wherein, before combining, the method further includes determining the direction of the fiber geometric axis within each of the plurality of composite tape lengths based, at least in part, on in at least one of the cross-sectional shape of the elongated empty space and the material property field of the transition region.
[00108] A19. The method according to any of paragraphs Al-A18, wherein, prior to combining, the method further includes establishing a relative location of each of the plurality of composite tape lengths within the radius filler based, at least in part, in at least one of the cross-sectional shape of the elongated empty space and the material property field of the transition region.
[00109] A20. The method according to any of paragraphs Al-A19, wherein, prior to combining, the method includes forming a layered stack of composite tape that includes at least a first length of composite tape and a second length of composite tape, in that a first fiber geometric axis direction of the first composite tape length is different from the second fiber geometric axis direction of the second composite tape length.
[00110] A21. The method according to any of the paragraphs Al-A20, wherein the combination includes combining so that each of the plurality of lengths of composite tape that defines an outer radius filler surface defines a fiber geometric axis direction that is parallel to a longitudinal geometric axis of the radius filler.
[00111] A22. The method according to any of the paragraphs Al-A21, wherein the combination includes combining with a pultrusion process.
[00112] A23. The method according to any of paragraphs Al-A22, wherein the combination includes combining with a pressing forming process.
[00113] A24. The method according to any of paragraphs Al-A23, wherein the combination includes: receiving the plurality of lengths of composite tape in a plurality of first openings on a first side of a forming die; pressing the plurality of lengths of composite tape against one another within the forming die to form the radius filler; and removing the radius filler from a second opening on a second side of the forming die, in which reception, pressing, and removal are carried out concurrently.
[00114] A25. The method according to paragraph A24, in which the conformation matrix defines a plurality of channels that extend between the plurality of first openings and the second opening, and in which the orientation includes selecting a relative orientation among the plurality of channels .
[00115] A26. The method according to any of the paragraphs Al-A25, in which the method also includes positioning the radius filler within the composite structure.
[00116] B1. A radius filler for the composite structure, wherein the composite structure includes a plurality of composite material veneers that converge into a transition region to define an elongated void, where the plurality of composite material veneers defines a field material property of the transition region, and furthermore in that the radius filler is configured to extend within the elongated void space, the radius filler comprising: a plurality of lengths of composite tape; wherein each of the plurality of lengths or composite tape includes a respective plurality of lengths of reinforcing fiber and a resin material; wherein the plurality of lengths of reinforcement fiber in each of the plurality of lengths of composite tape defines a fiber geometric axis direction; and furthermore, each of the plurality of composite tape lengths defines a respective fiber geometric axis direction which is selected based, at least in part, on the material property field of the transition region.
[00117] B2. The radius fill according to paragraph Bl, where the material property field of the transition region is at least one of a two-dimensional material property field of the transition region and a three-dimensional material property field of the transition region. transition.
[00118] B3. The radius filler according to any of paragraphs B1-B2, in which a material property field of the radius filler is at least one of: (i) corresponds to the material property field of the transition region; and (ii) conjugates the material property field of the transition region into a difference in the property field of boundary material at an interface between the transition region and the radius fill.
[00119] B4. The radius fill according to paragraph B6, in which the field difference of property of limit material is less than 50%, less than 40%, less than 30%, less than 20%, less than 15%, less than 10%, less than 5%, less than 2.5%, or less than 1% of the material ownership field in the transition region.
[00120] B5. The radius filler according to any of paragraphs B3-B4, wherein the material property field of the radius filler is at least one of a two-dimensional material property field of the radius filler and a three-dimensional material property field of the radius filler.
[00121] B6. The radius fill according to any of paragraphs B3-B5, in which the material property field of the transition region has a first field value in a first direction that extends along the elongated void, a second value of field in a second direction that is perpendicular to the first direction, and a third field value in a third direction that is perpendicular to the first direction and the second direction.
[00122] B7. The radius filler according to paragraph B6, in which the material property field of the radius filler corresponds to the material property field of the transition region in at least two, and optionally all, from the first direction, the second direction , and the third direction.
[00123] B8. The radius filler according to any of paragraphs B6-B7, in which the material property field of the radius filler corresponds to the material property field of the transition region in the second and third directions.
[00124] B9. The radius filler according to any of paragraphs B1-B8, in which the material property field of the transition region includes a stiffness field of the transition region, and optionally in which a material property field of the filler radius includes a stiffness field for the radius filler.
[00125] B10. The radius fill according to any of paragraphs B1-B9, in which the material property field of the transition region includes a thermal expansion coefficient field of the transition region, and optionally in which a property field of radius filler material includes a thermal expansion coefficient field of the radius filler.
[00126] Bll. The radius filler according to any of the Bl-BIO paragraphs, in which the material property field of the transition region includes a stress field of the transition region, and optionally in which a material property field of the filler radius includes a radius filler voltage field.
[00127] B12. The radius fill according to paragraph Bll, in which the stress field of the transition region defines a main stress region within the transition region and a main stress direction within the main stress region.
[00128] B13. The radius filler according to paragraph B12, wherein at least one of the plurality of composite tape lengths defines a respective fiber geometric axis direction that extends within a portion of the radius filler which is located within the region of main stress and at least substantially parallel to the main stress direction.
[00129] B14. The radius fill according to any of paragraphs B12-B13, wherein the principal stress direction is measured perpendicular to a longitudinal geometric axis of the elongated void.
[00130] B15. The radius filler according to any of paragraphs B12-B14, wherein one, or any, plane that passes through the radius filler and is perpendicular to the main stress direction intersects the plurality of reinforcement fiber lengths of at least one of the plurality of lengths of composite tape.
[00131] B16. The radius filler according to any of paragraphs B1-B15, wherein the radius filler defines an apex region within a plane that is perpendicular to a longitudinal geometric axis of the radius filler, and yet at least one of the The plurality of lengths of composite tape defines a respective fiber geometric axis direction which is directed into the apex region.
[00132] B17. The radius filler according to any of paragraphs B1-B16, wherein the material property field of the transition region includes a resin contraction field of the transition region which describes the contraction of resin material within the plurality of veneers of composite material during curing of the composite structure, and optionally wherein a material property field of the radius filler includes a resin contraction field of the radius filler that describes the contraction of resin material within the radius filler during healing of the composite structure.
[00133] B18. The radius filler according to any of paragraphs B1-B17, wherein the plurality of lengths of composite tape is in physical contact with each other within the radius filler.
[00134] B19. The radius filler according to any of paragraphs B1-B18, wherein the radius filler at least substantially, and optionally completely, fills the elongated void.
[00135] B20. The radius filler according to any of paragraphs B1-B19, wherein the plurality of composite material veneers includes a first composite material veneer, a second composite material veneer, and a third composite material veneer, wherein the first composite material veneer and the second composite material veneer define a first contact region between them, in which the second composite material veneer and the third composite material veneer define a second contact region between them, in which the third veneer composite material and the first composite material veneer define a third contact region between them, and yet the first contact region, the second contact region and the third contact region end within the elongated void space.
[00136] B21. The radius filler according to any of paragraphs B1-B20, in which the plurality of lengths of composite tape is not coplanar with each other.
[00137] B22. The radius filler according to any of paragraphs B1-B21, wherein at least one length of composite tape of the plurality of lengths of composite tape is in direct physical contact with and not coplanar with another of the plurality of lengths of composite tape.
[00138] B23. The radius filler according to any of paragraphs B1-B22, wherein the radius filler does not include a separate resin material that separates the plurality of composite tape lengths from one another.
[00139] B24. The spoke filler according to any of paragraphs B1-B23, wherein the spoke filler does not include a separate resin material that separates the plurality of composite tape lengths from one another.
[00140] B25. The radius filler according to any of paragraphs B1-B24, wherein at least one selected length of composite tape from the plurality of composite tape lengths is arranged at an angle of inclination with respect to at least a portion of a remainder of the plurality lengths of composite tape.
[00141] B26. The radius filler according to paragraph B25, in which the selected length of composite tape is a first length of composite tape, in which the angle of inclination is a first angle of inclination, and in which the radius filling includes a second length of composite tape which is arranged at a second angle of inclination with respect to the first length of composite tape and the portion of the remainder of the plurality of lengths of composite tape.
[00142] B27. Radius filling according to any of paragraphs B25-B26, wherein the angle of inclination is at least 5 degrees, at least 10 degrees, at least 15 degrees, at least 20 degrees, at least 25 degrees, at least 30 degrees at least 35 degrees, at least 40 degrees, or at least 45 degrees.
[00143] B28. Radius filling according to any of paragraphs B25-B27, wherein the angle of inclination is less than 90 degrees, less than 85 degrees, less than 80 degrees, less than 75 degrees, less than 70 degrees, less than 65 degrees , less than 60 degrees, less than 55 degrees, less than 50 degrees, or less than 40 degrees.
[00144] B29. The radius fill according to any of paragraphs B25-B28, wherein the angle of inclination is measured in a cross-section of the radius fill.
[00145] B30. The radius filler according to any of paragraphs B1-B29, wherein the radius filler defines at least one of a triangular cross-sectional shape, a wedge-shaped cross-sectional shape, and a cross-section which defines a base and a plurality of converged angled sides.
[00146] B31. The radius filler according to any of paragraphs B1-B30, wherein the plurality of lengths of composite tape includes at least 2, at least 4, at least 6, at least 8, at least 10, at least 15, at least 20, at least 30, at least 40, at least 50, at least 60, or at least 80 lengths of composite tape.
[00147] B32. The radius filler according to paragraph B31, wherein a number of lengths of composite tape that are included in the radius filler varies over a radius filler length.
[00148] B33. The radius filler according to any of paragraphs B1-B32, wherein each of the plurality of lengths of composite tape defines a length and a width.
[00149] B34. The radius filler according to paragraph B33, wherein the length of a portion of the plurality of composite tape lengths is at least one of: (i) at least 1 meter (m), at least 2 m, at least 3 m, at least 4 m, at least 5 m, at least 6 m, at least 7 m, at least 8 m, at least 9 m, at least 10 m, at least 15 m, or at least 20 m; and (ii) less than 50 m, less than 40 m, less than 30 m, less than 25 m, less than 20 m, less than 15 m, less than 10 m, or less than 5 m.
[00150] B35. The radius filler according to any of paragraphs B33-B34, wherein a width of a portion of the plurality of composite tape lengths is at least one of: (i) at least 3 millimeters (mm), at least 4 mm , at least 5 mm, at least 6 mm, at least 7 mm, at least 8 mm, at least 9 mm, at least 10 mm, at least 11 mm, at least 12 mm, at least 14 mm, at least 16 mm at least 18 mm, at least 20 mm, or at least 24 mm; and (ii) less than 50 mm, less than 45 mm, less than 40 mm, less than 35 mm, less than 30 mm, less than 25 mm, less than 20 mm, less than 18 mm, less than 16 mm, less at 14 mm, less than 12 mm, less than 10 mm, less than 8 mm, less than 6 mm, or less than 4 mm.
[00151] B36. The radius filler according to any of paragraphs B34-B35, wherein the portion of the plurality of composite tape lengths includes at least one length of composite tape, two lengths of composite tape, three lengths of composite tape, at least 25% the plurality of lengths of composite tape, at least 50% of the plurality of lengths of composite tape, at least 75% of the plurality of lengths of composite tape, or 100% of the plurality of lengths of composite tape.
[00152] B37. The radius filler according to any one of paragraphs B1-B36, wherein the plurality of reinforcement fiber lengths is formed from at least one of carbon, titanium, aluminum, a glass, and a metal.
[00153] B38. The radius fill according to any one of paragraphs B1-B37, wherein a longitudinal fiber axis of each of the plurality of reinforcement fiber lengths is substantially parallel to a fiber axis direction, in which the filling radius radius defines a longitudinal radius filling axis, and yet the direction of the fiber geometry axis is one parallel to, and oriented at a fiber angle with respect to the longitudinal geometric axis of the radius filling.
[00154] B39. The radius filler according to paragraph B38, wherein the fiber angle includes a fiber angle of at least one of: (i) at least 5 degrees, at least 10 degrees, at least 15 degrees, at least 20 degrees at least 25 degrees, at least 30 degrees, at least 35 degrees, at least 40 degrees, or at least 45 degrees; and (ii) less than 85 degrees, less than 80 degrees, less than 75 degrees, less than 70 degrees, less than 65 degrees, less than 60 degrees, less than 55 degrees, less than 50 degrees, or less than 40 degrees.
[00155] B40. The radius filler according to any of paragraphs B1-B39, wherein the plurality of lengths of reinforcement fibers forms a two-dimensional arrangement within at least a portion of the plurality of composite tape lengths, and optionally in which the two-dimensional arrangement includes at least one of a mesh, a woven structure, a cloth, and a random arrangement of reinforcement fibers.
[00156] B41. The radius filler according to any one of paragraphs B1-B40, wherein the plurality of lengths of reinforcement fibers form a three-dimensional arrangement within at least a portion of the plurality of composite tape lengths, and optionally in which the three-dimensional arrangement includes at least one of a mesh, a woven structure, a cloth, a random arrangement of reinforcement fibers, and two or more arrangements of two or more dimensions of reinforcement fibers that are stacked on top of each other.
[00157] Cl. A composite structure, comprising: the plurality of veneers of composite material that converge into a transition region to define an elongated empty space; and the radius fill according to any of paragraphs B1-B41, wherein the radius fill extends within the void.
[00158] C2. A composite structure according to paragraph Cl, in which the radius filler is operably attached to the plurality of composite material veneers.
[00159] C3. A composite structure according to any of paragraphs C1-C2, wherein the composite structure includes at least one of an aircraft, a portion of the aircraft, an aircraft fuselage cylinder, a portion of the aircraft fuselage cylinder, a wing of the aircraft aircraft, a portion of the aircraft wing, an aircraft stabilizer, and a portion of the aircraft stabilizer.
[00160] When used here, the terms “selective” and “selectively”, when modifying an action, movement, configuration, or other activity of one or more components or characteristics of a device, mean that the specific action, movement, configuration, or other activity is a direct or indirect result of the user manipulating an aspect of, or one or more components of, the device.
[00161] When used here, the terms "adapted" and "configured" mean that the element, component, or other matter is designed and / or intended to perform a given function. Thus, the use of the terms "adapted" and "configured" should not be interpreted to mean that a given element, component, or other matter is simply "capable of" performing a given function, but that the element, component, and / or other matter is specifically selected, created, implemented, used, programmed, and / or designed for the purpose of performing the function. It is also within the scope of this disclosure that elements, components, and / or other matters mentioned as being adapted to perform a particular function can additionally or alternatively be described as being configured to perform this function, and vice versa. Similarly, the material that is mentioned as being configured to perform a particular function can additionally or alternatively be described as being operative to perform this function.
[00162] The various exposed elements of apparatus and method steps exposed here are not required for all apparatus and methods in accordance with the present disclosure, and the present disclosure includes all new and non-obvious combinations and subcombination of the various elements and steps exposed here. In addition, one or more of the various elements and steps exposed here can define independent inventive material that is separate and apart from the total of an exposed apparatus or method. Consequently, such inventive material is not required to be associated with the specific apparatus and methods that are expressly set forth herein, and such inventive material may find use in the apparatus and / or methods that are not expressly set out here.

权利要求:
Claims (11)
[0001]
1. Method (400) of forming a radius filler (390) for a composite structure (30), wherein the composite structure (30) includes a plurality of composite material veneers (31) that converge into a region transition (40) to define an elongated void space (38), and even where the radius filler (390) is configured to extend into the elongated hollow space (38), the method (400) characterized by the fact that comprises: determining a cross-sectional shape of the elongated hollow space (38); determine a material property field in the transition region (40); and forming the radius filler (390), wherein the formation includes: combining a plurality of lengths of composite tape (160) to define a cross-sectional shape of the radius filler (390) corresponding to the cross-sectional shape the elongated void space (38), each of the plurality of lengths of composite tape (160) includes a respective plurality of lengths of reinforcing fiber (90) and a resin material (92), and yet each the plurality of lengths of composite tape (160) defines a fiber geometric axis direction (162); and orienting the plurality of reinforcement fiber lengths (90) each of the plurality of composite tape lengths (160) based, at least in part, on the material property field of the transition region (40), in which determining the material property field of the transition region (40) includes determining a principal stress region (80) within the transition region (40) and determining a principal stress direction (82) within the principal stress region ( 80), and furthermore that the orientation includes orienting in such a way that at least one of the plurality of composite tape lengths (160) defines a respective fiber geometric axis direction (162) that extends within a portion of the fiber filler. radius (390) which is located within the main stress region (80) and at least substantially parallel to the main stress direction (82).
[0002]
2. Method (400) according to claim 1, characterized by the fact that the determination of the cross-sectional shape of the elongated empty space (38) includes at least one among modeling the composite structure (30) and determining a desired shape of cross-section to the elongated empty space (38).
[0003]
3. Method (400) according to claim 1, characterized by the fact that the orientation includes orienting so that a material property field of the radius filler (390) corresponds to the material property field of the transition region (40 ).
[0004]
4. Method (400) according to claim 1, characterized by the fact that the orientation includes orienting so that a material property field of the radius filler (390) corresponds to the material property field of the transition region (40 ) within 20% of the material property field of the transition region (40) at an interface (70) between the transition region (40) and the radius filler (390).
[0005]
5. Method (400) according to claim 1, characterized by the fact that the determination of the material property field of the transition region (40) includes at least one among determining a two-dimensional material property field of the transition region (40) 40) and determine a field of property of three-dimensional material of the transition region (40).
[0006]
6. Method (400) according to claim 1, characterized by the fact that the material property field of the transition region (40) includes one or more of a field of stiffness of the transition region (40), a field of coefficient of thermal expansion of the transition region (40), and a stress field (80) of the transition region (40).
[0007]
Method (400) according to any one of claims 1 to 6, characterized in that, before combining, method (400) further includes determining the direction of the geometric fiber axis (82) within each of the plurality of lengths of composite tape (160) based, at least in part, on at least one of the cross-sectional shape of the elongated void space (38) and the material property field of the transition region (40).
[0008]
Method (400) according to any one of claims 1 to 7, characterized in that, before combining, method (400) further includes establishing a relative location of each of the plurality of lengths of composite tape (160 ) within the radius filler (390) based, at least in part, on at least one of the cross-sectional shape of the elongated void space (38) and the material property field of the transition region (40).
[0009]
Method (400) according to any one of claims 1 to 8, characterized in that the combination includes combining in such a way that each of the plurality of lengths of composite tape (160) defining an external radius filler surface (390) defines a fiber geometric axis direction (162) that is parallel to a longitudinal geometric axis (392) of the radius filler (390).
[0010]
Method (400) according to any one of claims 1 to 9, characterized in that the combination includes: receiving the plurality of lengths of composite tape (160) in a plurality of first openings (336) on a first side (332) of a forming matrix (306); pressing the plurality of lengths of composite tape (160) against each other within the forming die (306) to form the radius filler (390); and removing the radius filler (390) from a second opening (338) on a second side (334) of the forming die (306), in which reception, pressing, and removal are carried out concurrently.
[0011]
11. Method (400) according to any one of claims 1 to 10, characterized by the fact that the method further includes locating the radius filler (390) within the composite structure.

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同族专利:

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公开号 | 公开日

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RU2015102733A3|2018-07-06|

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CN104972671A|2015-10-14|

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US10035309B2|2018-07-31|

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US20180311913A1|2018-11-01|

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CN104972671B|2018-12-14|

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RU2015102733A|2016-08-20|

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US10864687B2|2020-12-15|

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JP2015199347A|2015-11-12|

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EP2933094A1|2015-10-21|

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AU2015200558A1|2015-10-22|

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KR20150115623A|2015-10-14|

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AU2015200558B2|2018-04-05|

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RU2668651C2|2018-10-02|

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EP2933094B1|2020-06-10|

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BR102015005662A2|2016-09-13|

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US20150283764A1|2015-10-08|

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JP6616089B2|2019-12-04|

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KR102266130B1|2021-06-17|

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法律状态:
2016-09-13| 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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2019-12-17| B06U| Preliminary requirement: requests with searches performed by other patent offices: procedure suspended [chapter 6.21 patent gazette]|

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2020-06-09| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|

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2020-07-14| 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 13/03/2015, 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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US14/244,690|2014-04-03|

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US14/244,690|US10035309B2|2014-04-03|2014-04-03|Radius fillers for composite structures, composite structures that include radius fillers, and systems and methods of forming the same|

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