Lattice reinforced radius filler

Patent metadata

Field	Value
Publication number	US-11897191-B2
Application number	US-202016916035-A
Country	US
Kind code	B2
Filing date	Jun 29, 2020
Priority date	Jun 13, 2014
Publication date	Feb 13, 2024
Grant date	Feb 13, 2024

Abstract

A method and apparatus for forming a radius filler. A lattice is formed of connecting elongate members having a three-dimensional shape of the radius filler. A resin is placed within the lattice.

First claim

What is claimed is:

1. An apparatus that comprises:
a lattice shaped as a one-piece additive manufactured structure that comprises unified elongate members that form a first curved peripheral side, a second curved peripheral side, and a third peripheral side, wherein:
a first elongate member of the unified elongate members extends from the first curved peripheral side to the second curved peripheral side: and
a second elongate member of the unified elongate members extends from the first curved peripheral side to the third peripheral side; and

a resin that fills all space between the unified elongate members in the lattice and forms a radius filler.

2. The apparatus of claim 1 , wherein the unified elongate members comprise a sintered powder.

3. The apparatus of claim 1 , wherein the resin is in a state selected from one of: a cured state, a partially cured state, and an uncured state, within the lattice and forms a radius filler.

4. The apparatus of claim 1 , wherein the lattice is selected from one of a regular lattice, an irregular lattice, a grid, a space frame, a Bravis lattice, and interconnected spring shapes.

5. The apparatus of claim 1 , wherein the lattice is comprised of a material selected from at least one of: a metal, a metal alloy, titanium, Invar, aluminum, steel, plastic, ceramic, a cured composite material, or carbon fibers.

6. The apparatus of claim 1 , wherein the resin is selected from one of: a thermoplastic polymer, a thermoset polymer, and a metal.

7. The apparatus of claim 3 , wherein a geometry of the unified elongate members in the lattice distributes loads in directions of an x-axis, a y-axis, and a z-axis for the radius filler in which the z-axis extends centrally through the radius filler.

8. A radius filler that comprises:
a lattice shaped as a one-piece additive manufactured structure that comprises a sintered metal powder configured to form unified elongate members that comprise: a first curved peripheral side, a second curved peripheral side, and a third peripheral side, configured to fill a channel in a composite part, wherein:
a first elongate member of the unified elongate members extends from the first curved peripheral side to the second curved peripheral side; and
a second elongate member of the unified elongate members extends from the first curved peripheral side to the third peripheral side; and

a resin that fills any space between the unified elongate members, wherein the lattice and the resin comprise a number of desired performance parameters that comprise a stiffness.

9. The radius filler of claim 8 , wherein the sintered metal powder is selected from one of titanium, steel, aluminum, Invar, and a metal alloy.

10. The radius filler of claim 8 , wherein the number of desired performance parameters further comprise at least one of: a load, a coefficient of thermal expansion, a toughness, a fracture resistance, or a strength.

11. A lattice shaped as a single additive manufactured structure configured to fill a void formed between walls of connected parts, such that the lattice comprises:
unified elongate members that form a first curved peripheral side, a second curved peripheral side, and a third peripheral side, of the lattice, wherein:
a first elongate member of the unified elongate members extends from the first curved peripheral side to the second curved peripheral side; and
a second elongate member of the unified elongate members extends from the first curved peripheral side to the third peripheral side;

the lattice conforms to a shape of the void and is configured to touch every wall of the void such that loads applied to the lattice distribute along an x-axis, a y-axis, and a z-axis; and
an interior infused with a resin that fills any space between the unified elongate members.

12. The lattice of claim 11 , wherein the elongate members comprise a sintered powder and a design configured to inhibit propagation of an inconsistency in a connection between the connected parts.

13. The lattice of claim 11 , wherein the unified elongate members are cured to each other.

14. The lattice of claim 11 , wherein a wall of the walls comprises a curved shape.

15. The lattice of claim 11 , wherein the unified elongate members comprise a metal.

16. The lattice of claim 11 , wherein the unified elongate members comprise titanium.

17. The lattice of claim 11 , wherein the void and the lattice each extend along the z-axis, such that the void forms a channel.

18. The lattice of claim 11 , wherein the unified elongate members comprise sintered powder.

19. The lattice of claim 11 , wherein the shape of the lattice conforms to a design from a computer-aided model of the connected parts.

20. The lattice of claim 19 , wherein the design comprises performance parameters, for a radius filler that comprises the lattice and the resin, selected from at least one of: a load, a coefficient of thermal expansion, a toughness, a fracture resistance, a stiffness, or a strength.

Assignees

• Boeing Co

Inventors

• Thomas Charles William
• Stephenson Benjamin Jeffrey

Classifications

• B64C1/064

  Stringers; Longerons · CPC title

• B29C64/153 Primary

  using layers of powder being selectively joined, e.g. by selective laser sintering or melting · CPC title

• B22F10/28

  Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM] · CPC title

• B22F10/60

  Treatment of workpieces or articles after build-up · CPC title

• B29C39/028

  having an axis of symmetry · CPC title