Folded composite filler

Patent metadata

Field	Value
Publication number	US-10065366-B2
Application number	US-201414287448-A
Country	US
Kind code	B2
Filing date	May 27, 2014
Priority date	May 27, 2014
Publication date	Sep 4, 2018
Grant date	Sep 4, 2018

Abstract

A method and apparatus for forming a composite filler. A composite ply is folded. The composite ply comprises fibers arranged at an angle relative to a central axis of the composite ply such that the composite filler has a varying cross-sectional orientation of fibers. A force is applied to the folded composite ply after folding to form a desired shape for the composite filler.

First claim

What is claimed is:

1. A method for forming a composite filler in a desired shape, the method comprising:
preparing a composite ply having a rectangular shape with a first side across from a third side and a second side across from a fourth side, the composite ply comprising a resin and a plurality of fibers;
folding the composite ply along at least one fold line parallel with a central axis of the composite ply to form at least a first part of the composite ply adjacent a second part of the composite ply, thus forming a folded composite ply;
wherein the central axis extends in a straight line continuously between a first midpoint of the first side and a second midpoint of the third side;
wherein all of the plurality of fibers in the composite ply extend diagonally, continuously, and parallel to each other, in a straight line, wherein a first portion of the fibers extend continuously from the first side to the second side, a second portion of fibers extend from the fourth side to the third side, and a third portion of fibers extend from the fourth side to the second side both before and after folding; and
applying a force to the folded composite ply to form the composite filler in the desired shape;
wherein the composite filler is formed in the desired shape only from the folded composite ply.

2. The method of claim 1 further comprising:
positioning the composite filler in a channel formed by a number of composite structures.

3. The method of claim 2 further comprising:
co-curing the composite filler and the number of composite structures.

4. The method of claim 2 further comprising:
positioning an adhesive on an outer surface of the composite filler before positioning the composite filler in the channel.

5. The method of claim 2 further comprising:
positioning a fabric ply on an inner surface of the channel prior to positioning the composite filler.

6. The method of claim 2 , wherein a wall of the channel is curved.

7. The method of claim 2 , wherein walls of the channel define a substantially triangular shape.

8. The method of claim 2 , wherein the channel is formed by a stringer and a skin panel.

9. The method of claim 8 , wherein the channel extends centrally through the stringer along an axis.

10. The method of claim 1 , wherein the central axis extends in a straight line continuously between a first midpoint of the first side and a second midpoint of the second side; and
wherein an orientation of the fibers relative to the central axis of the composite ply is selected from one of +/−10 degrees, +/−15 degrees, +/−30 degrees, +/−45 degrees, +/−60 degrees, and +/−75 degrees.

11. The method of claim 1 , wherein folding the composite ply comprises:
folding the composite ply along a first fold line to form a folded composite ply, wherein the first fold line is located along the central axis of the composite ply; and
folding the composite ply along a second fold line such that the fibers have a plus-and-minus fiber orientation along a length of the folded composite ply.

12. The method of claim 1 further comprising:
cutting the composite ply to have desired dimensions prior to folding the composite ply.

13. The method of claim 1 , wherein the composite ply is a single ply of composite prepreg tape.

14. The method of claim 1 , wherein the composite ply is a first composite ply and further comprising:
a second composite ply, wherein the first composite ply and the second composite ply form a two-ply stack of composite prepreg tape creating a plus-and-minus fiber orientation when folded.

15. A method for forming a composite filler in a desired shape, the method comprising:
cutting a composite ply to have a rectangular shape with a first side across from a third side and a second side across from a fourth side, wherein the composite ply is a ply of composite prepreg tape comprising fibers;
folding the composite ply along a fold line parallel with a central axis of the composite ply to form at least a first layer of the composite ply adjacent a second layer of the composite ply, thus forming a folded composite ply having at least two adjacent layers;
wherein all of the fibers in the composite ply extend diagonally, continuously, and parallel to each other, in a straight line, wherein a first portion of the fibers extend continuously from the first side to the second side, a second portion of fibers extend from the fourth side to the third side, and a third portion of fibers extend from the fourth side to the second side both before and after folding;
wherein the composite ply has a first side across from a second side and a third side across from a fourth side;
wherein the central axis extends in a straight line continuously between a first midpoint of the first side and a second midpoint of the third side;
applying a force to the folded composite ply the composite filler in the desired shape, wherein the composite filler is formed in the desired shape only from the folded composite ply;
positioning the composite filler in a channel formed by a number of composite structures; and
attaching the composite filler to the number of composite structures.

16. The method of claim 15 , wherein attaching the composite filler to the number of composite structures comprises:
co-curing the composite filler with the number of composite structures.

17. The method of claim 15 , wherein attaching the composite filler to the number of composite structures comprises:
co-bonding the composite filler with the number of composite structures.

18. The method of claim 15 , wherein the composite ply is a first composite ply and further comprising:
a second composite ply, wherein the first composite ply and the second composite ply comprise a two-ply stack of composite prepreg tape creating a plus-and-minus fiber orientation when folded.

19. The method of claim 15 , wherein the channel is formed by a stringer and a skin panel.

20. The method of claim 15 , wherein walls of the channel define a substantially triangular shape.

Assignees

• Boeing Co

Inventors

• Vetter Derek Paul
• Sommer Drew Edward

Classifications

• B29C70/34 Primary

  and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation} · CPC title

• B29L2031/3076

  Aircrafts (blades, propellers B29L2031/08) · CPC title

• B29C66/03

  After-treatments in the joint area (B29C66/3262 takes precedence) · CPC title

• B29L2009/00

  Layered products · CPC title

• B29C66/301 Primary

  Three-dimensional joints, i.e. the joined area being substantially non-flat (B29C66/5223, B29C66/5224, B29C66/5225 take precedence) · CPC title