Pre-filled radius layups

Patent metadata

Field	Value
Publication number	US-11279119-B2
Application number	US-201816016492-A
Country	US
Kind code	B2
Filing date	Jun 22, 2018
Priority date	Jun 17, 2014
Publication date	Mar 22, 2022
Grant date	Mar 22, 2022

Abstract

A void between two or more composite laminate parts is filled by a composite laminate filler that is laid up and integral with at least one of the parts.

First claim

What is claimed is:

1. A filler configured to fill a void between two composite laminate parts, the filler comprising:
a plurality of full plies and partial plies adhered on a radius edge on an outer full ply of only one of the composite laminate parts, wherein the partial plies and the full plies are interspersed with each other; and
wherein the partial plies are centered over the apex of the radius edge and have a cross sectional shape that substantially matches at least a portion of the void.

2. The filler of claim 1 , wherein a cross sectional shape of the plurality of partial plies is generally triangular.

3. The filler of claim 1 , wherein a partial ply is integrally laminated with the one of the composite laminate parts.

4. A composite radius filler configured to fill a void in a composite structure that comprises a part having a radius edge, the composite radius filler comprising a plurality of full plies interspersed with a plurality of partial composite plies integrally formed with the radius edge of only the part having the radius edge and collectively comprising a shape that substantially matches the void, wherein the partial plies are centered over the apex of the radius edge.

5. The composite radius filler of claim 4 , wherein the shape is generally triangular.

6. The composite radius filler of claim 4 , further comprising a second plurality of partial composite plies stacked in a substantially triangular shape and adhered to a cap on the void in the composite structure, such that the cap extends along the composite structure and the second plurality of partial composite plies comprises an apex that extends into the void.

7. A composite structure that comprises a filler in a void between a first radius edge of a first part, a second radius edge of a second part directly joined to the first part, and a third part, such that the composite structure comprises:
a first plurality of partial plies and a first plurality of full plies laid up only on the first radius edge of the first part and a second plurality of partial plies and a second plurality of full plies laid up only on the second radius edge of the second part; wherein the first plurality of partial ties are centered over the apex of the first radius edge of the first part and the second plurality of partial ties are centered over the apex of the second radius edge of the second part; wherein the first plurality of partial plies and the first plurality of full plies are alternated such that the first plurality of partial plies are interspersed between the first plurality of full plies; and wherein the second plurality of partial plies and the second plurality of full plies are alternated such that the second plurality of partial plies are interspersed between the second plurality of full plies.

8. The composite structure of claim 7 , wherein the first part having the first plurality of partial plies and the first plurality of full plies, the second part having the second plurality of partial plies and the second plurality of full plies, and the third part are joined to form the composite structure, wherein the void is substantially filled.

9. The composite structure of claim 7 , wherein the first plurality of partial plies and the second plurality of partial plies each respectively form a tapered shape that partially fills the void.

10. A composite structure that comprises:
a first plurality of full plies interspersed with a first plurality of partial plies laid up only on a first radius edge of a first part and a second plurality of full plies interspersed with a second plurality of partial plies only on a second radius edge of a second part joined to the first part, wherein the first plurality of partial ties are centered over the apex of the first radius edge of the first part and the second plurality of partial ties are centered over the apex of the second radius edge of the second part.

11. The composite structure of claim 10 , wherein the second part and a third part are joined to form the composite structure.

12. The composite structure of claim 10 , wherein the first plurality of full plies, the first plurality of partial plies, the second plurality of full plies, and the second plurality of partial plies substantially fill a void between the first radius edge, the second radius edge, and a third part.

13. The composite structure of claim 10 , wherein a shape of the first plurality of partial plies is generally triangular.

14. The composite structure of claim 12 , wherein a shape of the second plurality of partial plies is substantially triangular.

15. The composite structure of claim 14 , further comprising a third plurality of partial plies stacked onto a cap that extends along the composite structure.

16. The composite structure of claim 15 , wherein the third plurality of partial plies comprises a shape that comprises an apex that extends into the void.

17. The filler of claim 1 , wherein the two composite laminate parts are C-shaped.

18. The composite radius filler of claim 4 , wherein the part is C-shaped.

19. The composite structure of claim 7 , wherein the first part and second part are C-shaped.

20. The composite structure of claim 10 , wherein the first part and second part are C-shaped.

Assignees

• Boeing Co

Inventors

• Kisch Robert Arthur
• Jeffries Kyle

Classifications

• B32B5/22

  characterised by the presence of two or more layers which {are next to each other and are fibrous, filamentary, formed of particles or foamed (layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04)} · CPC title

• B32B3/02

  characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)} · CPC title

• B32B2307/558

  Impact strength, toughness · CPC title

• B32B2307/7265

  Non-permeable · CPC title

• B32B2250/00

  Layers arrangement · CPC title