ADVANCED VARIABLE RATE LAMINATED COMPOSITE RAY FILLING

专利摘要:
advanced variable radius laminated composite filler. The present invention relates to a composite radius filler (200) including a base portion (238) and a tip portion (220). the base portion (238) is formed of composite layers (258) that vary in full width along an overall longitudinal direction (202) and define a variable cross-sectional shape of the base portion (238) along the longitudinal direction. (202). the base portion (238) includes at least one transition zone (294) having a transition start (296) and a transition end (298) along the longitudinal direction (202). the composite layers (258) of the base portion (238) are arranged in one or more stacks (250) each stack having a predetermined fiber orientation angle sequence (262) and a changing stack width (278, 282) within the transition zone (294). the tip portion (220) includes a plurality of composite layers (258) formed in a generally triangular cross-sectional shape and stacked on top of the base portion (238).
公开号:BR102017020215A2
申请号:R102017020215-1
申请日:2017-09-21
公开日:2018-05-02
发明作者:Z. Forston Gabriel；Wen-Jun Su Benjamin；Rufino Russell
申请人:The Boeing Company；
IPC主号:

专利说明:

(54) Title: ADVANCED VARIABLE RAY LAMINATED COMPOSITE RAY FILLING (51) Int. Cl .: B32B 1/04; B32B 3/10; B64C 1/00 (30) Unionist Priority: 30/09/2016 US 15 / 282,616 (73) Holder (s): THE BOEING COMPANY (72) Inventor (s): GABRIEL Z. FORSTON; BENJAMIN WEN-JUN SU; RUSSELL RUFINO (74) Attorney (s): DANNEMANN, SIEMSEN, BIGLER & IPANEMA MOREIRA (57) Abstract: ADVANCED VARIABLE LAMINATED COMPOSITE RAY FILLING. The present invention relates to a composite radius filler (200) including a base portion (238) and a tip portion (220). The base portion (238) is formed by composite layers (258) that vary in total width along a global longitudinal direction (202) and define a variable cross-sectional shape of the base portion (238) along the longitudinal direction (202). The base portion (238) includes at least one transition zone (294) that has a transition start (296) and a transition end (298) along the longitudinal direction (202). The composite layers (258) of the base portion (238) are arranged in one or more stacks (250) each stack having a predetermined fiber orientation angle sequence (262) and a changing stack width (278, 282) within the transition zone (294). The tip portion (220) includes a plurality of composite layers (258) formed in a generally triangular cross-sectional shape and stacked on top of the base portion (238).
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Descriptive Report of the Invention Patent for FILLING COMPOSITE LAMINATED RAY WITH ADVANCED VARIABLE RADIUS.
FIELD [001] The present exhibition refers, in general, to composite structures and, more particularly, to a composite radius filler for a composite structure.
BACKGROUND [002] Composite structures are used in a wide variety of applications due to their high strength / weight ratio, corrosion resistance and other favorable properties. In aircraft construction, composites are used in increasing quantities to form the fuselage, wings, horizontal and vertical stabilizer and other components. For example, an aircraft wing can be formed by co-cured composite outer layer panels or co-attached to internal composite structures, such as composite wing ribs and composite wing spars. The ribs and composite wing spars can extend along a transverse direction from the wing root to the wing tip and generally can decrease the thickness along the horizontal direction to gradually reduce the stiffness of the rib or wing spar .
[003] The composite wing ribs and stringers can be supplied in a variety of cross sectional shapes. For example, a composite wing rib can be formed in a hat-shaped cross section and referred to as a ventilation wing rib or hat wing rib. In another example, a composite wing rib can be formed in a T-shaped cross section called the blade rib. A blade wing rib can be formed by joining two L-shaped loads in the coast-to-coast arrangement. Each of the loads in
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2/53 L-shape can have a flange and a web interconnected by a radiated web - flange transition. When the souls of two L-shaped loads are joined back to back, a longitudinal notch or partial cavity (for example, a radius-filled region) is formed between the opposite soul-flange transitions. To improve strength, stiffness and the durability of the wing rib and the connection between the wing rib and an outer layer panel, the cavity of the part is typically filled with a radius filler that can be referred to as a putty and which is normally formed of composite material.
[004] Composite ray fillers suffer from several disadvantages that impair their general usefulness. For example, certain radius filler materials may exhibit reduced structural performance due to susceptibility to cracking which can correspond to a relatively low tensile strength at the connection between the wing rib and an outer layer panel to which the wing rib is attached. connected. In addition, certain radius fill configurations have internal radii that vary along a longitudinal direction that can prevent non-destructive inspection (NDI) of the internal radii using acoustic inspection methods. In addition, certain radius fill configurations require the assembly of multiple components to form the radius fill and which has an adverse impact on costs and manufacturing schedule. In addition, certain wing rib configurations require radius fill with an asymmetrical shape that is difficult to manufacture using existing radius fill configurations.
[005] As can be seen, there is a need in the radius filler technique that provides improved structural performance, including reduced susceptibility to cracking, improved ability to adapt the rigidity and strength characteristics of
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3/53 improved traction. In addition, there is a need in the radius filler technique that improves the inspectability of the composite structure that contains the radius filler and which can also be manufactured economically and appropriately.
SUMMARY [006] The aforementioned needs associated with spoke fillers for composite structures are specifically addressed and alleviated by the present description which provides a composite spoke fill including a base portion and a tip portion. The base portion is formed by composite layers varying in total width along an overall longitudinal direction and defining a variable cross-sectional shape of the base portion along the longitudinal direction. The base portion includes at least one transition zone with a transition start and a transition end along the longitudinal direction. The composite layers of the base portion are arranged in one or more stacks each having a predetermined fiber orientation angle sequence and a stack width that changes within the transition zone. The tip portion includes a plurality of composite layers formed in a generally triangular cross-sectional shape and stacked on top of the base portion.
[007] A composite structure is also revealed that includes a pair of composite charges in contact back to back with each other and forming a longitudinal part cavity. In addition, the composite structure includes a radius filler installed in the part cavity. The spoke filling consists of a base portion and a tip portion. The base portion is formed by composite layers varying in total width along an overall longitudinal direction and defining a variable cross-sectional shape of the base portion along the longitudinal direction. The base portion includes at least
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4/53 minus a transition zone. The composite layers of the base portion are arranged in one or more stacks each having a predetermined fiber orientation angle sequence and a stack width that changes within the transition zone. The tip portion includes a plurality of composite layers formed in a generally triangular cross-sectional shape and stacked on top of the base portion.
[008] A method of manufacturing a radius filler is also disclosed. The method includes providing a base portion formed of composite layers varying in total width over at least a portion of an overall longitudinal direction and defining a variable cross-sectional shape of the base portion along the longitudinal direction. The base portion includes at least one transition zone. The composite layers of the base portion are arranged in one or more stacks of composite layers having a predetermined angular fiber orientation sequence and having a stack width. The stack width of at least one of the stacks changes within the transition zone. The method may additionally include providing a tip portion having a generally triangular cross-sectional shape and mounting the tip portion with the base portion to form a radius load in a condition as stacked. The method may additionally include applying heat and / or pressure to the spoke filler to produce a spoke filler with a variable cross-sectional shape.
[009] The characteristics, functions and advantages that have been discussed can be achieved independently in various modalities of this disclosure or can be combined in still other modalities, in addition to the details that can be seen with reference to the description and drawings below.
BRIEF DESCRIPTION OF THE DRAWINGS
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5/53 [0010] These and other characteristics of the present exhibition will become more evident by reference to the drawings in which similar numbers refer to similar parts by all of them and in which:
[0011] Figure 1 is a diagrammatic representation of a perspective view of an aircraft composed of one or more composite structures that incorporate one or more composite radius fillers, as disclosed herein;
[0012] Figure 2 is a schematic representation of a side view of an example of a composite wing rib configured as a blade rib and having a radius filler as disclosed herein;
[0013] Figure 3 is a diagrammatic representation of a sectional view of a composite wing rib (for example, a blade wing rib) taken along line 3 of Figure 2;
[0014] Figure 4 is a diagrammatic representation of an exploded sectional view of a composite wing rib in Figure 3 and illustrating a pair of L-shaped loads, a base load and a radius filler;
[0015] Figure 5 is a diagrammatic representation of a sectional view of the radius filler of Figure 4 in a condition so formed and that can be assembled with the wing rib of Figure 4;
[0016] Figure 6 is a schematic representation of a sectional view of the radius filler of Figure 5 in a condition as stacked and illustrating a base portion and a tip portion;
[0017] Figure 7 is a diagrammatic representation of a perspective view of a plurality of unidirectional cut ribbon cables that pass through a pultrusion matrix;
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6/53 [0018] Figure 8 is a diagrammatic representation of a perspective view of a longitudinal section of a unidirectional cut ribbon cable;
[0019] Figure 9 is a perspective view of the pultrusion matrix of Figure 7;
[0020] Figure 10 is a diagrammatic representation of a perspective view of a longitudinal section of a tip portion with a triangular cross-sectional shape;
[0021] Figure 11 is a diagrammatic representation of a sectional view of the tip portion taken along line 11 of Figure 10 and illustrating the non-planar cross-sectional shape of the cut ribbon cables as a result of being pultruded through the die pultrusion of Figure 9;
[0022] Figure 12 is a diagrammatic representation of a cross-sectional view of an example of a base portion of a radius filler in a condition as stacked and being assembled from a plurality of three-layer stacks in which each stack contains three composite layers;
[0023] Figure 13 is a diagrammatic representation of a perspective view of the first two cells of the base portion of Figure 12 and illustrating each three-layer pile having a non-zero grade + layer, a non-zero grade layer - and a layer of degree zero between the layer of degree non-zero + and the layer of degree non-zero -;
[0024] Figure 14 is a schematic representation of a sectional view of a radius filler in a stacked condition and further illustrates an excess vertical fill of the radius filler in relation to a cross-sectional profile of a partial cavity in that the beam filler in a condition as formed must be installed;
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7/53 [0025] Figure 15 is a diagrammatic representation of a sectional view of a radius filler in a condition as stacked prior to installation in a forming matrix;
[0026] Figure 16 is a diagrammatic representation of a cross-sectional view of the application of heat and pressure to the radius filler within the forming matrix;
[0027] Figure 17 is a diagrammatic representation of a sectional view of the radius filler in the condition thus formed after removal of the forming matrix;
[0028] Figure 18 is a schematic representation of a perspective view of a longitudinal section of a blade wing rib with a constant gauge area interconnected by a variable gauge transition zone for a constant gauge offset at one end the wing rib;
[0029] Figure 19 is a diagrammatic representation of a sectional view of a radius filler taken along line 19 of Figure 18 and illustrating the radius filler in the formed condition and which can be installed in a gauge section heavy in the area of the wing rib of Figure 18;
[0030] Figure 20 is a diagrammatic representation of a sectional view of a radius filler in the formed condition for a light gauge section of a wing rib (not shown); [0031] Figure 21 is a diagrammatic representation of a cross-sectional view of the top three-layer stack of the base portion of Figures 19 and 20 and illustrating the three composite layers that make up the three-layer stack;
[0032] Figure 22 is a diagrammatic representation of a sectional view of a radius filler taken along line 22 of Figure 18 and illustrating the radius filler in the formed condition and which can be installed in the deviation of the rib. wing of Figure 18;
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8/53 [0033] Figure 23 is a diagrammatic representation of a sectional view of the upper two-layer stack of the base portion of Figure 22 and illustrating the two composite layers that make up the two-layer stack;
[0034] Figure 24 is a diagrammatic representation of a side view of a composite wing rib configured as a hat wing rib;
[0035] Figure 25 is a diagrammatic representation of a sectional view of the wing rib taken along line 25 of Figure 24 and illustrating a pair of asymmetric ray fillers installed in the hat wing rib;
[0036] Figure 26 is a diagrammatic representation of a sectional view of a radius filler taken along section 26 of Figure 27 and illustrating the radius filler material with an asymmetrical shape in a condition so formed;
[0037] Figure 27 is a diagrammatic representation of a cross-sectional view of a radius filler in a condition of as stacked with an asymmetrical shape and which can be formed in the asymmetric form of the radius filler of Figure 26 in a condition of so formed for installation in a partial cavity, resulting in the radius filling having an asymmetrical shape in the condition of thus assembled;
[0038] Figure 28 is a diagrammatic representation of a cross-sectional view of a radius filler with an asymmetrical shape in the stacking condition prior to installation in an asymmetrically shaped forming matrix;
[0039] Figure 29 is a diagrammatic representation of a sectional view of the application of heat and pressure to the radius filler within the forming matrix;
[0040] Figure 30 is a diagrammatic representation of a view 870170070807, of 9/21/2017, p. 15/239
9/53 is in section of the radius filler having an asymmetrical shape in a condition so formed after removal of the forming matrix;
[0041] Figure 31 is a diagrammatic representation of a perspective view of a longitudinal section of a base portion of a radius filler illustrating the shape of the variable cross section of the base portion and further illustrating a stack termination of one of the batteries in the base portion;
[0042] Figure 32 is a diagrammatic representation of a perspective view of an example of a longitudinal section of a composite stringer with a longitudinal cavity in which the radius filler must be installed and further illustrating the additions of localized layers and layers in the wing rib corresponding to the transition zones in the base portion of the radius filler;
[0043] Figure 33 is a diagrammatic representation of a schematic top view of a bottom stack of a base portion of a symmetrical radius filler that has transition zones that are displaced from the beginning of a layer portion or an addition of layers in a wing rib on which the radius filler should be installed;
[0044] Figure 34 is a diagrammatic representation of a top view of a base portion of a radius filler that illustrates a transition zone within which one of the stacks of the base portion ends;
[0045] Figure 35 is a diagrammatic representation of a side sectional view of a base portion illustrating the termination of one of the 0 degree layers within the transition zone at each of the opposite ends of the radius filler;
[0046] Figure 36 is a diagrammatic representation of an enlarged view of the first two stacks of the base portion and illustrating
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10/53 the termination of the layer within the transition zone of the 0 degree layers of each of the cells;
[0047] Figure 37 is a diagrammatic representation of a top view rotated 180 ° of the transition zone at an inner end of the base portion of Figure 35 and illustrating the spacing of the zero degree layer terminations;
[0048] Figure 38 is a diagrammatic representation of a top view of the transition zone at the outer end of the base portion of Figure 35 and illustrating the spacing of the zero degree layer terminations;
[0049] Figure 39 is a diagrammatic representation of a top view of an example of a two-layer stack added to the bypass and ending within the transition zone of the radius filler;
[0050] Figure 40 is a flow diagram that illustrates one or more operations that can be included in a method of manufacturing a composite radius filler.
DETAILED DESCRIPTION [0051] Referring now to the drawings in which the exhibitions are for the purpose of illustrating various preferred modes of disclosure, shown in Figure 1 is an aircraft 100 that has a fuselage 102 that extends from a front end to a rear end of the aircraft 100. The rear end may include one or more tail surfaces for directional control of the aircraft 100, such as a vertical stabilizer 108 and a pair of horizontal stabilizers 110. The airplane 100 may further include a pair of wings 106 extending out of fuselage 102 and one or more propulsion units 104. Fuselage 102, wings 106, vertical stabilizer 108, horizontal stabilizers 110 and other aircraft components can be formed as structure 870170070807, of 21/09 / 2017, p. 17/239
11/53 composite strips 118, one or more of which may incorporate one or more composite radius fillers 200 (Figure 3), as disclosed herein. For example, as shown in Figure 1, the wings 106 of an aircraft 100 can include a plurality of internal composite wing ribs 120 and composite wing spars 170 (for example, Figure 32), each of which includes one or more fillers radius 200 and which can be co-cured or co-attached to an outer layer panel 116. Wing ribs 120 and shoulders 170 can be oriented along a horizontal direction of each wing 106 and can, in general , decrease in thickness or caliber along the extension direction as a means to gradually reduce the stiffness of the wing rib 120.
[0052] Figure 2 is a side view of a composite wing rib 120 that incorporates a radius 200 filler (Figure 3) as described herein. In the example shown, the wing rib 120 is configured as a blade wing rib 121 (Figure 3). As described in greater detail below, the gauge of the rib can generally vary (for example, decrease) along a longitudinal direction 202 of the wing rib 120. In addition, the gauge of the wing rib can be reduced at the ends 126 of the wing. wing rib (e.g., deviations 124 - Figure 18) to reduce the rigidity of wing rib 120 and thereby avoid stress concentrations at the ends 126 of the wing rib.
[0053] Figure 3 is a sectional view of an example of a wing rib 120 (i.e., a blade wing rib 121) having a T-shaped cross section. Figure 4 is an exploded view of the rib wing 120 of Figure 3. Figures 3-4 illustrate a pair of L 130 loads, a base load 128 and a radius filler 200 that make up the wing rib 120. The L 130 shaped loads and the load of base 128 are each formed as a laminaPetição 870170070807, of 21/09/2017, p. 18/239
12/53 of composite layers 258. Each of the L-shaped loads 130 includes a flange 134 and a core 132 interconnected by a core - flange 136 transition. The core - flange 136 transitions have an internal radius 138 and a external radius 140. In a blade wing rib 121, webs 132 may be oriented with respect to flanges 134 at a web angle 218 ranging from 90 ° to 75 ° or less. In a blade wing rib 121, the web angle 218 can vary along the longitudinal direction of the wing rib 121. However, in some instances, the web angle 218 of a blade wing rib 121 may be constant. along the longitudinal direction of the wing rib 121.
[0054] The souls 132 of the L 130-shaped charges can be brought into contact back to back with each other, resulting in a longitudinal cavity 142 (for example, a radius-filled region) between the transitions of web - flange 136 opposite of L-shaped loads 130. The radius filler 200 is dimensioned and configured to fill partial cavity 142 when base load 128 is mounted to L-shaped loads 130. After assembly, loads 130 L-shaped, the radius filler 200 and the base charge 128 can be co-attached or co-cured to an outer layer panel 116 (Figure 1). In an alternative embodiment not shown, the base load 128 can be omitted, and the L-shaped loads 130 and the radius filler 200 can be mounted directly on an outer layer panel 116 for co-bonding or co-curing.
[0055] Although radius filler 200 of the present description is initially described in the context of a blade wing rib 121 (Figures 3-4), radius filler 200 can be incorporated into any of a variety of different configurations of wing rib and stringer and is not limited to a wing rib
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13/53 of blade 121. For example, as described below, fillers of radius 200 with an asymmetrical shape 214 (Figure 26) can be embedded in a wing rib 120 with a cross-section in the shape of a hat and which can be referred to like a wing rib of a hat 172 (Figures 24-25). In addition, the radius filler 200 can be incorporated into a composite structure 118, such as a composite stringer 170 (Figure 32) that has an I beam cross section (not shown). However, the radius filler 200, currently disclosed, can be incorporated into any of a variety of different composite structure configurations and is not limited to incorporation into a composite wing rib 120 or a composite stringer 170.
[0056] Figure 5 is a sectional view of the composite radius filler 200 of Figure 4 in a condition as formed 206 (for example, Figures 17 and 30). The radius filler 200 condition thus formed 206 is an intermediate form between the condition as stacked (for example, figures 6 and 27) and the condition thus assembled 207 (for example, figures 3 and 25). The radius filler 200 in the condition of thus formed 206 is configured to be installed within a partial cavity 142 of a composite structure 118. For example, a radius filler 200 in a condition of the thus formed 206 can be installed within a cavity partial 142 between the back-to-back L-shaped loads 130 (Figures 3-4) of a blade wing rib 121. The part cavity 142 has opposite cavity sides 144 (Figures 3-4) defined by the respective radii opposite faces 140 (Figure 4) of the flange web transitions 136.
[0057] The radius filler sides 210 may have a variable radius along a longitudinal direction 202 of at least a portion of the radius filler 200 to accommodate variPetition external radii 870170070807, from 9/21/2017, pg. 20/239
14/53 levels 140 of the partial cavity 142 along the longitudinal direction 202. In the assimilated condition 206, the filling sides of the opposite radius 210 are preferably contoured in addition to the cavity sides 144. When the filling of radius 200 in the condition thus formed 206 is installed in the part cavity 142, the radius filler 200 assumes the mounting condition 207 (for example, Figures 3 and 25) in which the radius filler sides 210 conform to the external radii 140 on the sides of the partial cavity 144. The contour (eg radii) of the radius 210 filling sides in condition 207 as assembled may be slightly different (eg different radii) from the contour (eg the radii) of the filling sides radius 210 in the condition thus formed 206.
[0058] Figure 6 is a sectional view of the radius filler 200 of Figure 5 in a stacked condition 204 before forming in the condition thus formed 206. The radius filler 200 includes a base portion 238 and a portion of tip 220 positioned on top of base portion 238. Base portion 238 is formed by composite layers 258 that vary in total width along longitudinal direction 202 (Figure 2) of transition zone 294 (Figure 18). In this regard, the base portion 238 has a variable cross-sectional shape within the transition zone 294. The transition zone 294 (Figure 18) has a transition start 296 (Figure 18) and a transition end 298 (Figure 18) as described below.
[0059] As shown in Figures 5-6, the composite layers 258 of the base portion 238 are arranged in one or more stacks 250. Each stack 250 is formed as a laminated load of composite layers 258 arranged in a predetermined sequence of angle 262 fiber orientation, as shown in figures 13, 21 and 23, and described below. Composite layer material can be a
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15/53 pre-impregnated fiber-reinforced polymer matrix material (i.e., pre-impregnation) having a plurality of reinforcement fibers impregnated with thermoset or thermoplastic matrix material or resin. In one example, the prepreg material may be an epoxy resin / carbon fiber prepreg. Pre-impregnation can be provided in a relatively small layer thickness (for example, Figure 21). For example, pre-impregnation can be provided in a standard layer thickness 260 of approximately 0.0076 inches, although the composite layers 258 used to form the radius filler 200 that is currently disclosed can be provided in any thickness without limitation. For example, pre-impregnated layers can be supplied in thicknesses as small as several thousand inches, as large as one or more than ten thousand inches, or in any thickness between them.
[0060] In Figure 6, each of the stacks 250 in the base portion 238 has a stack width 278, 282 (e.g., Figure 31) that is complementary to the width of the partial cavity 142 (e.g., the partial cavity in the stringer composite composite support 170 from Figure 32) at the vertical location of stack 250. As described below, the width of stack 278, 282 of at least one of the cells 250 in the base portion 238 changes or tapers within transition zone 294 (Figure 34) of the radius filler 200. However, in sections of the radius filler 200 outside transition zone 294, the stacks 250 have a constant cell width 278, 282. For example, the cell width 278, 282 is constant in area 122 (Figure 34) and in deviation 124 (Figure 34) of radius 200 filling, as described below.
[0061] In figure 6, the tip portion 220 consists of a plurality of composite layers 258 formed in a generally triangular cross section shape and stacked on top of Portion 870170070807, of 9/21/2017, pg. 22/239
16/53 base 238. In one example, composite layers 258 in tip portion 220 are unidirectional cut ribbon cables 222. Unidirectional cut ribbon cables 222 can be formed by cutting sheets of pre-layered composite material impregnated along a longitudinal direction to form a plurality of cables of relatively narrow width. For example, cut ribbon cable 222 can be supplied in ¹ Λ inch, ¹ Z> inch widths, or any of a variety of different cable widths. The reinforcement fibers in each unidirectional cut ribbon cable 222 are oriented in a single direction that is parallel to the longitudinal direction of the cut ribbon cable 222. However, the tip portion 220 can be made up of other cable shapes and is not limited to unidirectional cut ribbon cable 222.
[0062] Figure 7 shows an example of a system for manufacturing the tip portion 220 of a radius filler 200. In the example shown, a plurality of unidirectional cut ribbon cables 222 are removed from the spools 224 and are passed through a pultrusion matrix 310. Figure 8 illustrates a longitudinal section of a cut ribbon cable 222 that can be pulled from a reel 224. The unidirectional cut ribbon cable 222 has a relatively small layer thickness 260 (for example, approximately 0, 0076 inches) and can have a cable width 226 between approximately 0.12 and 0.50 inches before pultrusion with other cut ribbon cables 222 through the pultrusion matrix 310. In one embodiment, the tip portion 220 of the filler radius 200 can consist of anywhere from 4 to 9 cut ribbon cables 222 each with a cable width 226 of approximately 0.25 inches. However, a tip portion 220 can be manufactured with less than 4 cables or more than 9 cables. In addition, a tip portion 220 can be manufactured from cut ribbon cables 222 with a
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17/53 226 cable width other than 0.25 inch. In addition, a tip portion 220 can be manufactured from cut ribbon cables 222 in two or more different cable widths 226. Figure 9 is a perspective view of an example of a pultrusion die 310 having a die opening through which cut ribbon cables 222 are passed to shape and consolidate cut ribbon cables 222 in a triangular shape of cross section.
[0063] Figure 10 illustrates a longitudinal section of the tip portion 220 that can have a size and cross-sectional shape that is generally constant over the length of the tip portion 220. However, a tip portion 220 can be manufactured in such a way that the tip portion 220 has a variable cross-sectional shape along one or more longitudinal sections of the tip portion 220. For example, one or more cut ribbon cables 222 can be added or removed during the manufacturing process (e.g., pultrusion) a tip portion 220, resulting in tip portion 220 having a variable cross-section size and / or shape along longitudinal direction 202. In one embodiment, tip portion 220 of size and / or cross-sectional shape can be configured to vary in correspondence with the change of outer radii (Figure 3-4) of partial cavity 142 (Figures 3-4) of a composite structure 118.
[0064] Figure 11 is a sectional view of the tip portion 220 of Figure 10 illustrating the shape of the non-flat cross section of each cut ribbon cable 222 as a result of cut ribbon cables 222 being crushed together during cutting. pultrusion through the pultrusion matrix 310. The tip portion 220 has an apex of the tip portion 236, opposite sides of the tip portion 234 and a lower surface of the tip portion 228. The lower surface of the tip portion 228 can generally be flat to facilitate stacking the
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18/53 tip portion 220 on top of base portion 238. Advantageously, the manufacture of tip portion 220 from unidirectional cut ribbon cables 222 improves the fabrication and structural performance of radius filler 200 over fill fill radius 200 with tip portions 220 including laminated composite layers 258.
[0065] Figure 12 is a sectional view of an example of a base portion 238 of a radius filler 200 assembled from a plurality of three-layer stacks 254 each containing three composite layers 258. The base portion 238 has a staggered pyramidal cross-sectional shape composed of a lower stack 276 and one or more medium stacks 280 mounted on top of the lower stack 276. Depending on the longitudinal location in the radio pad 200, the base portion 238 can include in any instead of 3 to 20 stacks 250 (for example, including lower stack 276 and medium stacks 280) of composite layers 258. However, a base portion 238 can include any number of stacks 250. The base portion section 238 containing three-layered stacks 254 is located in the surface area 122 (Figure 18) of the radius filler 200. As described below, at an offset 124 of the radius filler 200, the base portion 238 includes a plurality of stack two-layer s 256 due to layer 274 termination of the 0-degree layers 264 within transition zone 294 interconnecting area 122 to offset 124.
[0066] Figure 13 is a perspective view of the first two three-layer cells 254 of the base portion 238 of Figure 12, wherein each three-layer cell 254 consists of a non-zero grade layer + 266, a layer non-zero degree 270, and a 0 degree 264 layer located between the degree + non-zero layer 266 and the non-zero degree layer 270. Each of the composite layers
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19/53
258 in the three-layer stack 254 is a unidirectional layer with reinforcement fibers oriented in a single direction. For arrangements where the composite layers 258 are each approximately 0.0076 inches thick, each three layer stack 254 has a pile thickness 252 of approximately 0.0228 inches. The absolute value of the fiber orientation angle 262 of the non-zero grade layer + 266 and the non-zero grade layer - 270 is equal, so that each stack of three layers 254 is a balanced configuration to minimize thermal stresses during curing. The fiber orientation angle 262 of the non-zero grade layer + 266 and the non-zero grade layer 270 is preferably less than 45 degrees. For example, in a preferred embodiment, the fiber orientation angle sequence 262 of each three-layer stack 254 consists of a +30 degree layer 268, a -30 degree layer 272 and a 0 degree layer 264 located between the +30 degree layer 268 and the -30 degree layer 272. Advantageously, when assembling the base portion 238 from three-layer stacks 254 instead of stacks 250 with four or more composite layers 258, the rigidity characteristics of the radius filler 200 along the longitudinal direction 202 can be controlled more precisely by adding or removing stacks 250.
[0067] Figure 14 is a sectional view of a radius filler 200 in a stacked condition 204 (shown in continuous lines) illustrating a vertical fill 248 of radius filler 200 in relation to the cross-sectional profile of the partial cavity 142 (shown in broken lines) in which the radius filler 200 in the condition thus formed 206 (for example, Figure 17) must be installed. The dashed lines in Figure 14 represent the shape and size of the partial cavity 142 as defined by the opposite sides of the cavity 144 that extend from the base of the cavity 146 to the
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20/53 apex of cavity 148. The distance from the base of cavity 146 to the apex of cavity 148 defines the height of cavity 150. As mentioned above, the opposite cavity sides 144 are defined by the opposite external radius 140 of the composite back loads with wing rib backs 120, as well as the L-shaped back-to-back loads 130 shown in Figures 3-4. The cavity base 146 is defined by the base load 128 (Figure 3-4) or outer crust panel 116 (Figure 1) to which the wing rib 120 is finally co-cured or co-attached. As mentioned above, when the radius filler 200 in the condition as formed 206 (for example, Figures 17 and 30) is installed in the partial cavity 142, the radius filler 200 assumes the condition of thus assembled 207 (for example, Figures 3 and 25) in which the radius filling sides 210 conform to the external radii 140 of the partial cavity sides 144. The contour (for example, the radii) of the radius filling sides 210 in the condition as mounted 207 can be slightly different (for example, different radii) from the contour (for example, the radii) of the radius 210 filling sides in the condition thus formed 206.
[0068] In Figure 14, the vertical filler 248 can be provided by a filler radius 200 in the stacked condition 204 that has a cross-sectional area that overfills the cross-sectional area of the partial cavity 142. In this regard, the the tip portion 220 has a lower surface of the tip portion 228, and the base portion 238 has a lower surface of the base portion 246 and a height of the base portion. The base portion 238 is designed to provide radius filler 200 in the condition that as stacked 204 with a vertical filler 248 of partial cavity 142 according to the following criteria: (1) the height 242 of the base portion as stacked from the filler radius 200 in the condition as empiPetição 870170070807, of 9/21/2017, p. 27/239
21/53 side 204 is at least 5 percent greater than a height 243 of the base portion, thus assembled, of radius filler 200 in condition 207 as assembled and (2) height 242 of the base portion, as stacked, the radius filler 200 in the condition as stacked 204 is at least a thickness 260 of the additional layer (for example, Figures 21 and 23) beyond the height 243 of the assembled base portion. The height 242 of the stacked base portion is extended from the bottom surface of the base part 246 to the bottom surface of the tip part 228 of the radius filler 200 on condition that as stacked 204. The height 243 of the base portion mounted to from the base of the cavity 146 to the location of the lower surface of the tip portion 228, if the tip portion 220 were installed in the cavity of part 142 such that the tip portion 220 is in the condition as assembled 207.
[0069] The location of the bottom surface of the tip part 228 when the radius filler 200 is in the condition so assembled 207 can be determined by analysis or by measuring (for example, physically, by ultrasound in a laboratory, etc.) of the bottom surface of the tip portion 228 in relation to the cavity base 146 with the tip portion in the part cavity 142 and conformed to the sides of the part cavity 144 in the condition as assembled 207. The location of the bottom surface of the part tip 228 is such that the cross-sectional area of the tip portion 220 in the condition as mounted 207 is equal to the cross-sectional area of the tip portion 220 in the condition as stacked 204. The widths of one or more composite layers 258 added to meet the overflow vertical criteria 248 described above can be substantially equivalent (for example, within ± 0.010 inches) for the width of the partial cavity 152 at the intersection 285 of the sides of cavity 144 with a median plane 284 of CApetition 870170070807, of 9/21/2017, p. 28/239
22/53 additional composite layers 258. To one or more additional composite plates 258 for vertical overfilling 248 can be added on top of the middle stacks 280 of the base portion 238 as long as stacked 204.
[0070] In the example in Figure 14, the one or more composite layers 258 added to meet the criteria of vertical overfill 248 comprise three additional composite layers 258 (for example, a stack of three layers 254) added to meet the criteria of excess vertical fill 248. However, in other examples, the addition of one or more composite layers 258 to vertical fill 248 may be a single composite layer 258, two composite layers 258 or more than three composite layers 258 added to satisfy requirements for vertical overfilling 248 described above in any longitudinal section of a wing rib 120. In one example, the overfilling vertical criteria 248 can be met by adding at least one three-layer stack 254 (as described above), such as in the area 122 of a wing rib 120. In the deviation 124 of a wing rib 120, the criteria of vertical overfill 248 pod to be met by adding at least one two-layer 256 stack (as described below). Although the vertical fill 248 is at least 5 percent as described above, the vertical fill 248 is not necessarily constant over the length of the radius fill 200 and can vary with changes in the caliper of the wing rib and / or with changes in web angle 218 (Figures 25-27) between webs 132 and flanges 134, as described below. In this regard, the nose portion 220 has a nose portion height 232, a nose portion width 230 and a nose portion side shape 234 that can change with changes in the wing rib and / or angle soul 218,
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23/53 as described in greater detail below.
[0071] Referring further to Figure 14, as mentioned above, the partial cavity 142 has opposite cavity sides 144, respectively, defined by the opposite external radii 140 of the composite back-to-back loads (Figures 3-4). The base portion 238 consists of a single bottom stack 276 and a plurality of medium stack 280 on top of the bottom stack 276. Each of the middle stack 280 has an average stack width 282 that is adjusted to the nominal width of the partial cavity 142. In this regard, the base portion 238 as stacked 204 can be designed with minimal or no overfill in the horizontal direction. More specifically, the average width of the stack 282 of each of the average stacks 280 of the base portion 238 in the stacked condition 204 is substantially equivalent (for example, within ± 0.010 inches) to the width of the partial cavity 152 at the intersection 285 of the sides cavity 144 with a median plane 284 of the respective median stack 280.
[0072] In addition, the bottom stack 276 has a bottom stack width 278 that is less than the width of the partial cavity 152 on the bottom surface of the cavity of part 142. Preferably, the width of the bottom stack 278 is approximately 0, 10 inches (± 0.010 inches) less than the width of the bottom of the partial cavity 153 which can be defined as the distance between the intersections or the tangency of the sides of the cavity 144 with the base load 128 (Figure 3) or outer layer panel 116 to which the wing rib 120 is co-attached or co-cured. Advantageously, it has been found that the design of the radius filler 200 to have an excess vertical fill 248 and a minimal or nonexistent horizontal fill significantly improves the compactness of the radius filler 200 and reduces the cracking susceptibility in the radius filler 200, in relation to
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24/53 reduced amount of compaction provided by radius fillings that depend on horizontal overfill. Improved compaction and reduced crack susceptibility due to the use of vertical filler 248 in radius filler 200, which is currently disclosed, advantageously improves the structural performance of wing rib 120, as well as the improved extraction capacity.
[0073] Figure 15 shows a filler radius 200 in a stacked condition 204 and inverted prior to installation in a matrix cavity 302 of a forming matrix 300 in a non-limiting example of a system to form the stacked condition 204 of the radius 200 fill to a condition of thus formed 206. In this regard, any of a variety of systems (not shown) can be implemented to form a radius 200 fill, as stacked 204, in a radius 200 fill as formed 206. In Figure 15, matrix cavity 302 can substantially duplicate the size and shape of partial cavity 142 of composite structure 118 in which radius filler 200 is to be installed in the condition thus formed 206. Although not shown, the matrix cavity 302 can be contoured in addition to longitudinal variations in the opposite external radii 140 (Figures 3-4) of partial cavity 142.
[0074] Figure 16 shows the radius filler 200 installed in the forming matrix 300 and encapsulated by a pressure plate 304 mounted on top of the forming matrix 300. Also shown is the application of heat 308 and / or pressure 306 to the radius filler 200 within forming matrix 300. Heat 308 and / or pressure 306 can be applied to radius filler 200 in a pressure cycle - predetermined heat for debulk and / or consolidation of radius filler 200. The application of heat 308 can reduce viscosiPetition 870170070807, of 9/21/2017, p. 31/239
25/53 of the resin in the pre-impregnated composite layers 258 and the cut ribbon cables 222 that make up the radius filler 200, allowing the composite material under pressure 306 to adapt to the cross-sectional shape of the die cavity 302.
[0075] Figure 17 shows the radius filler 200 in the condition thus formed 206 after the removal of the forming matrix 300. When the radius filler 200 is within the forming matrix 300, heat 308 can be applied in order to avoid complete curing of the resin such that the radius filler 200 can be removed from matrix cavity 302 in a partially cured green state. The radius filler 200 in the condition thus formed 206 can be installed in the partial cavity 142 of a composite structure 118 such that the radius filler 200 conforms to the contour of the partial cavity side 144 and the radius filler 200 it is in a condition as mounted 207 as described above, for final co-curing and / or co-bonding with the composite loads that make up the wing rib 120.
[0076] Figure 18 shows a longitudinal section of an example of a blade wing rib 121 that has a constant gauge area 122 connected by a variable gauge transition zone 294 to a constant gauge offset 124 at the end of the rib of wing rib 126 of wing rib 120. As mentioned above, area 122 of wing rib 120 and radius filler 200 can be described as a constant gauge section that is not located bypass 124. Transition zone 294 can be described as a wing rib section 120 and radius filler 200 that is variable gauge from a constant gauge section to another constant gauge section. Offset 124 can be described as a constant gauge section of wing rib 120 and radius filler 200. Offset 124 can be located at one end of
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26/53 wing rib 126 or at both wing rib ends 126. In the example of a wing rib 120 of an outer wing layer, radius filler 200 may include an offset 124 at the inner end 112 (Figure 38 ) of the wing rib 120, at the outer end 114 (Figure 38) of the wing rib 120, or both, at the inner end 112 and at the outer end 114 of the wing rib 120. The thickness or caliber of the wing rib 120 and of the radius 200 fill at a deviation 124 is relatively thin compared to the thickness in the constant gauge areas 122 of the radius 200 fill.
[0077] Figure 19 is a sectional view of the radius filler 200 in the condition thus formed 206 and which can be mounted with the wing rib 120 of Figure 18 in the constant gauge area 122 of the wing rib 120. In a In this embodiment, the tip portion 220 of radius filler 200 in area 122 preferably includes 4 to 9 cut ribbon cables 222, each of which may be approximately 0.25 inches wide. However, the tip portion 220 can include any number of cut ribbon cables 222 of any cable width 226. The base portion 238 of the radius filler 200 in the surface area 122 preferably includes 5 to 17 three-layer stacks 254, although the base portion can include any number of three-layer stacks 254.
[0078] Figure 19 is an example of a radius filler 200 that can be installed in a relatively heavy gauge area 122 of a wing rib 120. The radius filler 200 may have a tip portion 220 containing 16 continuous cut ribbon 222 each with a cable width 226 of approximately 0.125 inch, or 8 continuous cut ribbon cables 222, each with a cable width 226 of approximately 0.25 inch. The base portion 238 of the radius filler 200 in Figure 19 consists of
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27/53 in 14 three-layer stacks 254. As a stacked condition (not shown), the bottom stack 276 of the base portion 238 may have a bottom stack width (not shown) of approximately 1.1 inches and the stack upper average 286 (for example, located directly below tip portion 220) can have a stack width (not shown) of approximately 0.16 inches.
[0079] Figure 20 illustrates an example of a radius filler 200 in a condition thus formed 206 for a section of relatively small gauge 122 area, and where the tip portion described above 220 contains the 8 cut ribbon cables 222 above mentioned 0.25 inches wide. The base portion 238 of the radius filler 200 in Figure 20 consists of 6 three-layer stacks 254. In Figure 20, in the stacking condition (not shown), the bottom stack 276 of the base portion 238 has a lower stack width (not shown) of approximately 0.73 inches and the upper average stack 286 may have an average stack width (not shown) of approximately 0.20 inches.
[0080] Figure 21 is a sectional view of the top three-layer stack 254 286 of the base portion 238 of Figures 19 and 20 and illustrating the three composite layers 258 that make up the three-layer stack 254. As mentioned above, for a layer thickness 260 of approximately 0.0076 inches, the thickness of stack 252 of each three layer stack 254 is approximately 0.0228 inches. In a preferred embodiment, each three-layer stack 254 in the base portion 238 of surface area 122 preferably has a fiber orientation angle sequence 262 consisting of a +30 degree layer 268, a layer of - 30 degrees 272 and a 0 degree 264 layer located between the +30 degree 268 layer and the -30 degree 272 layer.
[0081] Figure 22 is a sectional view of the radius filler
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28/53
200, taken at constant gauge deviation 124 of wing rib 120 of Figure 18. The tip portion 220 in a deviation 124 preferably includes 4 to 9 0.25 inch wide ribbon cables 222. The base portion 238 of the radius filler 200 in a deflection 124 preferably includes 5 to 10 two-layer cells 256. A two-layer cell 256 does not contain grade 0 264 layers and is formed due to the termination in the transition zone 294 of the 0-degree layer 264 of the three-layer stack 254. In this respect, terminating the 0-degree layer 264 in the transition zone 294 results in deviation 124 consisting of the degree + non-zero layer 266 and the degree layer ^- no -zero 270 in contact with the back to back. Each two-layer stack 256 in the base portion 238 of a bypass 124 preferably has a fiber orientation angle sequence 262 consisting of a +30 degree 268 layer and a -30 degree 272 layer. radius 200 illustrated in Figure 22, the base portion 238 consists of 6 three-layer stacks 254.
[0082] Figure 23 is a sectional view of the upper two-layer stack 256 286 of the base portion 238 of Figure 22. The two composite layers 258 that make up the two-layer stack 256 are a +30 degree layer 268 and a layer 272 of -30 degrees and which are a continuation of such layers in the three-layer stack 254. For a layer 260 thickness of approximately 0.0076 inches, the thickness of stack 252 of a two-layer stack 256 is approximately 0.0152 inches.
[0083] Figure 24 is a side view of a hat wing rib 172 with a hat-shaped cross section. Figure 25 is a sectional view of the hat wing rib 172 taken along line 25 of Figure 24 and illustrating a pair of asymmetric radius fillers installed in the hat wing rib 172. The nerPetition 870170070807, of 9/21 / 2017, p. 35/239
29/53 hat wing vura 172 can consist of a planar base load 128, a trapezoidal wrapping load 178, a hat-shaped primary load 176 and a pair of asymmetric radius fillers 200. The base load 128 , wrapping load 178 and primary load 176 can be formed separately as a composite plate laminate 258. Mounting of base load 128, wrapping load 178 and primary load 176 results in a pair of part cavities 142 In the hat wing rib 172, the souls 132 may be oriented at a non-perpendicular web angle 218 to the flanges 134. In some examples, the web angle 218 on each side of the hat wing rib 172 can be up to 105 ° or more. However, a single wing wing rib 172 may have souls 132 that are oriented at a perpendicular web angle 218 to flanges 134. For examples of hat wing rib 172, where webs 132 are oriented in one non-perpendicular web angle 218, partial cavity 142 has opposite external radii 140 which can be uneven. However, the opposing external radii 140 may be the same along one or more longitudinal and uneven sections along one or more other longitudinal sections of a hat wing rib 172 which have perpendicular web angles 218 or non-web angles. perpendiculars 218. The web angle 218 for the hat wing rib 172 can be constant along the longitudinal direction of the wing rib 172. However, in other examples, the web angle 218 for the hat wing rib 172 may vary along the longitudinal direction of the wing rib 172.
[0084] In Figure 25, the radius filler 200 in the condition as stacked 204 is dimensioned and configured to fill the part cavity 142 when the base load 128 is assembled with the envelope load 178 and the primary load 176. After the assembly, the
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30/53 base load 128, wrap load 178, primary load 176 and radius fillers 200 can be co-attached or co-cured to an outer layer panel 116 (Figure 1). In an alternative embodiment not shown, the base load 128 can be omitted, and the wrap load 178, primary load 176 and radius fillers 200 can be mounted directly on an outer layer panel (not shown) to co-install. healing or co-bonding.
[0085] Figure 26 is a sectional view of a radius 200 filler in a condition so formed 206 that can be installed in a partial cavity of the hat wing rib 172 of Figure 25. The radius 200 filler in a condition thus formed 206 has an asymmetrical shape 214 in which the opposite radius filler sides 210 have unequal outer radii 140, as distinguished from a radius filler 200 with a symmetrical shape 212 around a vertical center line as shown in Figure 5, in which the external radii 140 of the opposite radius filling sides 210 are the same. The asymmetrically shaped radius filler material 200 of Figure 26 includes the tip portion 220 and the base portion 238, and is constructed in a similar manner to the above described construction of a symmetrically shaped radius filler 200. In addition, the radius filler 200 of Figure 26 incorporates the vertical fill criteria 248 described above.
[0086] Figure 27 is a sectional view of an example of a radius filler 200 in a stacked condition 204 having an asymmetric shape 214. In a preferred embodiment, the asymmetric radius filler 200 can be formed in a condition of thus formed 207 (for example, see Figures 28-30) and mounted with a wing rib 120 to result in the condition as mounted 207 of radius filler 200 shown in Figure 25. However, in an alternative embodiment not shown, a filling of
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31/53 symmetrically shaped radius 200 in a condition of how stacked 204 can be formed into a radius 200 filler in a condition of so formed 206 with an asymmetric shape 214 and which can be mounted with a wing rib 120 to result in assembled condition 207 shown in Figure 26.
[0087] Figures 28-30 illustrate an example of a process for forming a radius 200 filler with an asymmetric shape 214 in a condition of as stacked 204 in a radius 200 filler with an asymmetric shape 214 in a condition of like formed 206. Figure 28 illustrates a radius filler 200 having an asymmetric shape 214 in a condition as stacked 204 prior to installation in an asymmetrically formed matrix cavity 302 of a forming matrix 300 that can substantially duplicate the asymmetric shape of a partial cavity 142 in which radius filler 200 is to be installed. The insertion of the radius filler 200 in the die cavity 302 and / or the application of heat 308 and / or pressure 306 causes the tip portion 220 and the base portion 238 to conform to the outline of the matrix cavity 302.
[0088] Figure 29 shows the application of heat 308 and / or pressure 306 to the radius filler 200 within the forming matrix 300 after a pressure plate 304 is mounted on top of the forming matrix 300. The application of pressure 306 and the reduction of resin viscosity due to the application of heat 308 causes the base portion 238 and the tip portion 220 to conform to the sides of the die cavity 302. Figure 30 shows the radius filler 200 in the condition of as formed 206 with an asymmetrical shape 214 after removal of forming matrix 300. As indicated above, radius filler 200 in the condition of thus formed 207 can be installed in a partial cavity of a wing rib 120 to result in radius filler shown in condition 207 mounted on
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Figure 25.
[0089] In any of the examples disclosed herein, a filler radius 200 in the condition as stacked 204, in the condition thus formed 206 and / or in the condition 207 as assembled may have a symmetrical shape 212 that is constant throughout an entire length of the radius filler 208. In other examples, a radius filler 200 in the condition as stacked 204, in the condition as thus formed 206 and / or in the condition as assembled 207 may have an asymmetric shape 214 that is constant throughout over a total length of the radius filler 208. However, in other embodiments not shown, a radius filler 200 in the condition as stacked 204, in the condition thus formed 206 and / or in the condition thus assembled 207 may include a or more longitudinal sections that have a symmetrical shape 212 that transits along the length of the radius filler 200 to an asymmetrical shape 214. A radius filler 200 can have a symmetrical shape 212 (Figure 9) in a condition of how stacked 204 along an entire length of padding 200, and at least a portion of the length of the radially symmetrically filled pad 200 in the condition that how stacked 204 can be formed in an asymmetric form 214 (Figure 26) and / or mounted in an asymmetric part cavity 142. In a preferred embodiment of a blade wing rib 121, radius filler 200 can be provided in a symmetrical form 212 in a condition of as stacked 204 and a condition of thus formed 206 and may have an asymmetric shape 214 in a condition as mounted 207 along at least a longitudinal portion of the radius 200 filler when installed in the partial cavity 142 of the blade wing rib 121. In a preferred embodiment of a wing rib hat 172, a radius 200 filling can be provided asymmetrically 214 in
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33/53 a stacking condition 204 and a condition of so formed 206 and may have an asymmetric shape 214 in a condition of so mounted 207 along at least a longitudinal portion of the radius filler 200 when installed in the partial cavity 142 of the rib with hat 172.
[0090] Figure 31 is a perspective view of a longitudinal section of a base portion 238 composed of a plurality of stacks 250. The base portion 238 has a variable cross-sectional shape as a result of tapering in the stack widths 278 , 282 of one or more of the stacks 250. In addition, Figure 31 illustrates the termination of the upper stack 286 of the base portion 238. As shown, a terminating end of a stack 250 may have a non-square shape such as a shape generally pointed or rounded (not shown) and which can improve the ability of radius filler 200 to fill the volume of partial cavity 142. However, a terminating end of a stack 250 can be square in shape (not shown) . As mentioned above, changes in stack width 278, 282 and addition or removal of stacks 250 are limited to transition zones 294 of a radius fill 200. The surface area 122 and the offset 124 of a radius fill 200 have constant stack widths 278, 28 and have no additions or withdrawals of stacks 250. A transition zone 294 can interconnect a pair of surface sections 122, or a transition zone 294 can connect an area of area 122 to an offset 124 (Figure 37-38) located at one or both opposite ends of a radius 200 fill. Transition zone 294 comprises a change in at least one of a general base part width 240 (Figure 14) and a height of base portion 242 (Figure 14) in correspondence with the location of parts of layers 156 and / or additions of layers 162 along the
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34/53 longitudinal direction 202 of the composite structure 118 in which the radius filler 200 is to be installed.
[0091] Figure 32 shows a longitudinal section of a composite stringer 170 illustrating a partial cavity 142 in which a radius 200 filler must be installed. Also shown is the change thickness of stringer 170 along the longitudinal direction 202 as a result. of additions of layers located 162 and parts of layers 156 in stringer 170. Additions of layers 162 and parts of layers 156 may result in variations in the outer radii 140 (Figures 3-4) along the longitudinal direction 202 of stringer 170. Advantageously, the variable cross-sectional shape of the radius filler 200 is complementary to the variations in the external radii 140 of the stringer 170. In this way, the internal radius 138 (Figures 3-4) of the stringer 170 can be substantially constant along the longitudinal direction 202 which can improve the inspectability of the stringer 170 and can reduce manufacturing costs. As described below, a symmetrical radius filler 200 (for example, Figure 5) can be mounted on a composite structure (for example, a symmetrical composite stringer) in such a way that the longitudinal location of the transition zones 294 is slightly offset from the longitudinal location of layer removals156 and / or layer additions in the composite structure.
[0092] Figure 33 is a schematic top view of a bottom stack 276 of a base portion 238 of a symmetrical radius filler 200 (for example, Figure 5) showing the offset 154 of a transition zone 294 from the start 158 to end 160 of a layer 156 reduction in a wing rib 120 having a symmetrical cross section (for example, Figure 3), and showing offset 154 of another transition zone 294 from start 164 to end 166 of an addition of 162 layers to the wing rib 120. The beginning of
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35/53 transition 296 of a transition zone 294 may be located after the start 158 of a layer 156 fall and the transition end 298 of transition zone 294 may be located after the end 160 of layer 156 reduction. additions of layers 162 to the wing rib 120, the transition start 296 of a transition zone 294 can be located before the start 164 of a layer addition 162 and the transition end 298 of transition zone 294 can be located before the end 166 of layer 162 addition. For radius fill with a symmetrical shape (for example, Figure 5), a transition zone 294 can be displaced 154 from the beginning of a layer 156 reduction or layer 162 addition by a distance of approximately 0.10 to 0.50 inches or more. As indicated above, the displacement of the transition zone 294 from the beginning and end of the layer reductions 156 and the addition of layers 162 in the wing rib 120 improves the ability of the radius filler 200 to fill the partial cavity 142 and which results in an improvement in strength, rigidity and inspectability of the composite structure 118. For asymmetric radius fillers 200 (for example, Figure 28), the transition zones 294 may not be offset from the reductions 156 or additions 162 of the layer.
[0093] Figure 34 is a top view of a base portion 238 of a radius filler 200 in a condition as stacked 204 and illustrating a transition zone 294 interconnecting two sections of surface area 122. As noted above , within each section of area 122, the stack widths 278, 282 of the stacks 250 in the base portion 238 are constant and there are no additions or reductions of stacks 250 (that is, without stack terminations), the combined effect of which results in the radius filler sides 210 (Figure 5) having a constant radius along the length of the surfaces 122. Within the transition zones 294, one or more batteries 250 poPetition 870170070807, from 9/21/2017, pg. 42/239
36/53 must be added or discarded. At a cell termination 288, all covers 258 on cell 250 end in the same location as shown in Figure 35, described below. In the example in Figure 34, stack termination 288 is shown located approximately midway between transition start 296 and transition end 298. However, a radius filler 200 can include any number of transition zones 294 in any location along the longitudinal direction 202 of the radius filler 200 in correspondence with the reductions 156 and the additions of layers 162 in the wing rib 120. [0094] For transition zones 294 that have two or more stack ends 288, the spacing between stack ends 288 and transition start 296 and transition end 298 can be equal to the length of transition zone 294 divided by the total number of stack ends 288. Also, within each transition zone 294, the stack widths 278, 282 of one or more of the stacks 250 may change or vary linearly between adjacent area sections 122. In Figure 34, a change in stack width 278, 282 may comprise a taper the 290 extending from the beginning of transition 296 to the end of transition 298. In the example shown, the stacks 250 have taper angles 292 that differ from each other. The combined effect of stack terminations 288 and changes in stack width 278, 282 in a transition zone 294 results in the filling sides of radius 210 (Figure 5) with a variable radius along the longitudinal direction 202 of transition zone 294 .
[0095] Figure 35 is a schematic side sectional view of a base portion 238 of a radius filler 200 in the condition as stacked 204 and illustrating a stack termination 288 of a three layer stack 254 within a zone. transition 294 connecting two sections of areas 122 in the longitudinal environment approximates Petition 870170070807, of 21/09/2017, p. 43/239
37/53 of the radius 200 filler. Layer 274 terminations of 0 degree 264 layers are also shown in a transition zone 294 at each between the inner end 112 and the outer end 114 of the radius filler 200 and in that each transition zone 294 connects an area 122 to an offset 124. In transition zones 294 at the inner end 112 and the outer end 114, the 0-degree layer 264 in each of the three-layer stacks 254 ends at a termination of line 274 located at the beginning of transition 296, at the end of transition 298, or within transition zone 294.
[0096] Advantageously, prior to the provision of the base portion 238, a plurality of three-layer stacks 254 can be manufactured by placing a three-layer laminate (not shown) consisting of a non-zero grade + layer sheet (not shown) ), a sheet of grade nãozero layer (not shown) and a 0 degree layer sheet (not shown) located between the sheets (not shown) the degree nãozero layer and the degree of layer ^- nãozero. As shown in Figure 35, a sheet for the 0 degree layer 264 of a stack 250 can be provided in a length that extends from the transition zone 294 at a wing rib end 126 to the transition zone 294 at the end of opposite wing rib 126. However, although not shown, the present description contemplates that a 0 degree layer 264 can extend beyond one end of the radius 200 filler. One sheet for the non-zero grade + layer 266 and the non-zero grade layer 270 can be provided in equal lengths. In addition, a sheet for the non-zero grade layer 266 and the non-zero grade layer 270 can each be longer than the sheet for the 0 degree layer 264 such that the stacks 250 will extend beyond the ends of the part (for example, exPetition 870170070807, of 9/21/2017, p. 44/239
38/53 tremor of the wing rib) and can be cut at a later time. In addition, the 266 grade + non-zero layer sheet and the non-zero grade layer sheet 270 can be provided in a length such that the ends of the 266 grade + non-zero layer and the non-zero degree 270 extends beyond each of the opposite ends of the 0 degree layer 264, as shown in Figure 35. After assembly, the three-layer laminated sheet can be cut along a longitudinal direction 202 in a plurality of individual three-layered stacks 254, each having the necessary stack width 278, 282 as described above in relation to Figure 14. The individual three-layered stacks 254 can be stacked on top of each other to form the shape of staggered pyramidal cross section of the base portion 238 with the required vertical filler 248, as described above and illustrated in Figure 14.
[0097] Referring further to Figure 35, when assembling the stacks 250 to form the base portion 238, the individual stacks 250 can be staggered along a longitudinal direction 202 so that, in the transition zones 294, the terminations layer 274 of the 0 degree 264 layers are spaced from one another. More specifically, for transition zone 294 on at least one wing rib end 126, layer terminations 274 are spaced apart from each other and from transition start 296 and transition end 298 by a distance approximately equal to the length of the transition zone 294 divided by the total number of terminations of layer 274 (for example, 0 degree layers 264) at the beginning of transition 296, at the end of transition 298 and / or within transition zone 294. The termination of the 0 degrees 264 of a three-layer stack 254 results in a two-layer stack 256 containing a grade + non-zero layer 266 and a non-zero grade layer
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270 in back-to-back contact, as shown in Figure 36. [0098] Figure 37 is a 180 ° rotated top view of the transition zone 294 at the inner end 112 of the base portion 238 of Figure 35 and showing spacing equal to s between the layer 274 terminations of the 0 degree 264 layers. Figure 38 is a top view of the transition zone 294 at the outer end 114 of the base portion 238 of Figure 35 and showing the spacing s of the zero degree layer terminations. 274. The spacing s at the inner end 112 and the outer end 114 can be determined using the following relationship:
s = x _in ex _{out rental company} (Equation 100) where:
Xin = TZin / din ^X out ^{= TZ} out ^{/ d} out [0099] TZ _in = length of transition zone 294 at the inner end 112 [00100] TZ _out = length of transition zone 294 at the outer end 114 [00101] TZin * TZout [00102] Din = number of layers of 0 degrees 264 fallen in deviation 124 at the inner edge 112 [00103] Dout = number of layers of 0 degrees 264 fallen in deviation 124 at the outer edge 114 [00104] As indicated above, a rib wing 120 can be configured so that the transition zone 294 at one end of the wing rib 120 is different in length from the transition zone 294 at the opposite end of the wing rib 120. For example, in Figures 37-38, the transition zone 294 at the inner end 112 is longer than transition zone 294 at the outer end 114. In that case, the distance d from the end of
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40/53 transition 298 to the nearest zero degree layer termination can be described using the following relationship:
d = TZ _in - (d _in -1) (s) (Equation 110) [00105] Figure 39 is a top view of an example of a two-layer stack 256 added to branch 124 and ending at stack termination 288 within the transition zone 294 of the radius filler 200. The two-layer stack 256 can be added to increase the height of the base portion 238 at offset 124 to meet the above-mentioned vertical overlap criteria 248 (Figure 14). As indicated above, vertical overfill 248 improves wing rib compaction 120 and reduces crack susceptibility, which improves the structural performance of wing rib 120, such as improved extraction force. In the example shown, stack termination 288 of the added two-layer stack 256 can be located midway between transition start 296 and transition end 298. For transition zones 294 that have two or more stack terminations 288 ( (not shown) pieces of pieces 256 originating at offset 124, the stack terminations 288 may be equally spaced apart and from the transition start 296 and the transition end 298.
[00106] Figure 40 is a flow diagram illustrating one or more operations that can be included in a method 400 of making a composite radius filler 200. Step 402 of method 400 includes providing a base portion 238 formed by composite layers 258 varying in total width over at least a portion of an overall longitudinal direction 202 and defining a variable cross-sectional shape of the base portion 238 along the longitudinal direction 202. As described above, the base portion 238 includes at least one transition zone 294 that has a transition start 296 and a transition end 298 to the
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41/53 along the longitudinal direction 202. The composite layers 258 of the base portion 238 are arranged in one or more stacks 250. Each stack 250 comprises a laminated load of composite layers 258 having a predetermined sequence of fiber orientation angle 262 and having a cell width 278, 282. The cell width 278, 282 of at least one of the cells 250 changes within the transition zone 294.
[00107] The step of providing the base portion 238 includes providing at least one stack 250 of the base portion 238 as a laminated filler in the form of a three-layer stack 254 (Figure 13) consisting of a + grade layer zero 266, a non-zero 270 degree layer and a 0 degree 264 layer laminated between the non-zero 266 degree layer and the non-zero 270 degree layer. The absolute values of the fiber orientation angle 262 the degree + non-zero layer 266 and the degree - nonzero layer 270 are the same (for example, ± 5 degrees). In a specific embodiment, the step of providing at least one stack 250 of the base portion 238 includes providing at least one stack 250 of the base portion 238 as a laminated filler consisting of a +30 degree 268 layer, a -30 layer degrees 272 and a 0 degree 264 layer located between the +30 degree 268 layer and the -30 degree 272 layer.
[00108] As mentioned above, changes in stack width 278, 282 are limited to transition zone 294 and do not occur in surface area 122 or offset 124 which are constant gauge sections of radius filler 200. Changes in stack width 278, 282 vary linearly and form a taper 290 (Figure 34) extending from the beginning of transition 296 to the end of transition 298. At least two of the stacks 250 have taper angles 292 that differ from one another. For example, Figure 34 illustrates a
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42/53 tapering 290 in each of the stacks 250 in the transition zone 294 which is shown interconnecting a pair of sections of area 122 on opposite sides of the transition zone 294.
[00109] In addition to decreasing stack widths 278, 282 within transition zone 294, the method may also include terminating, at least one of the cells 250, the 0 degree layer 264 at a line termination 274 located within of a transition zone 294. As a result of layer 274 termination of a 0-degree layer, a three-layer stack 254 (for example, in an area 122) transitions to a two-layer stack 256 consisting of degree + non-zero layer 266 (for example, a layer of + 30 degrees 268) and the layer of non-zero degree 270 (for example, a layer of -30 degrees 272) in back to back contact, as is illustrated in Figure 36. The step of finishing a 0 degree layer 264 comprises locating the termination of layer 274 at the beginning of transition 296, within transition zone 294 (that is, between the beginning of transition 296 and the end of transition 298), or at the end of transition 298. In some instances, a plurality of 0 degree 264 layers may be terminated as shown in Figure 38. In that arrangement, the method may include spacing of layer 274 terminations from 0 degree layers 264 separated from one another and from transition start 296 and transition end 298 to approximately equal spacing s the length of transition zone 294 divided by the total number of layer 274 terminations at the beginning of transition 296, within transition zone 294, and at transition end 298, similar to the arrangement shown in Figure 37. The terminations of layers 274 in an opposite end of the radius filler 200 may also use the same spacing between some of the layer 274 terminations and may have a different distance d between the layer 274 termination located closest to transition 870170070807, of 9/21/2017, pg. 49/239
43/53, similar to the arrangement described above in relation to Figure 38. [00110] Step 404 of method 400 includes providing a tip portion 220 that has a generally triangular cross-sectional shape as shown in Figure 6. The step of providing the tip portion 220 may include pultrusion of a plurality of pre-impregnated unidirectional cut ribbon cables 222 into the generally triangular cross-sectional shape. For example, Figure 7 illustrates an example of a system that can be implemented to draw a plurality of unidirectional cut ribbon cables 222 from the spools 224 and pass the unidirectional cut ribbon cables 222 through a pultrusion matrix 310 as shown in Figure 9. In one example, unidirectional cut ribbon cables 222 (Figure 8) can be provided in a cable width 226 between approximately 0.12 to 0.50 inches before pultrusion to the generally triangular cross-sectional shape, although others cable widths 226 are included.
[00111] Step 406 of method 400 includes stacking the tip portion 220 on the base portion 238 to form a radius filler 200 in a stacked condition 204, an example of which is illustrated in Figure 6 above. As mentioned above, radius filler 200 is configured to be installed in a partial cavity 142 of a composite structure 118. The part cavity 142 has a cavity height 150 measured from a cavity base 146 to a cavity apex. 148. The tip portion 220 has a tip portion bottom surface 228. The base portion 238 has a base portion bottom surface 246 and a base portion height 242.
[00112] Method 400 includes forming radius filler 200 with an excess vertical filler 248 (Figure 14) of partial cavity 142. As mentioned above, vertical filler 248 in
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Excess 44/53 can be achieved by designing the radius filler 200 in such a way that: (1) the height of the base portion as stacked 242 of the radius filler 200 under the condition that as stacked 204 is at least 5 percent greater than a height 243 of the base portion, thus assembled, of the radius filler 200 in the condition of so assembled 207, and (2) the height of the base portion as stacked 242 of the radius filler 200 in the condition as stacked 204 is at least an additional layer thickness 260 (for example, Figures 21, 23) in addition to the height of the base portion 243. As mentioned above, the excess vertical fill 248 of the radius filler 200 in a partial cavity 142 advantageously results in improved compaction of the composite structure 118 (eg wing rib 120) and reduces crack susceptibility which translates into an improvement in the structural performance of wing rib 120, including improved resistance to the pull force of wing rib 120.
[00113] In some examples, the radius filler 200 may be formed with excess vertical filler 248 and without excess horizontal filler. In this regard, the method may include forming the base portion 238 from a single lower stack 276 and a plurality of medium stacks 280 each having a stack width 282 corresponding to the nominal width of the partial cavity 142 as shown in Figure 14. In this regard, the method may include forming the radius filler 200 in the condition that it is stacked 204 such that the stack width 282 of each of the middle stacks 280 is substantially equivalent (within ± 0.010 inches) ) to the width of the partial cavity 152 at the intersection of the sides of the cavity 144 with the median plane 284 of the intermediate stack 250, as described above in relation to Figure 14. The lower stack 276 has a lower stack width 278 which is smaller than the partial cavity width 152 on a partial cavity bottom surface
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45/53
142 (Figure 14). For example, the width of the lower stack 278 is approximately 0.10 inches (± 0.010 inches) less than the width of the bottom of the partial cavity 153.
[00114] Step 408 of method 400 includes applying heat 308 and / or pressure 306 to the radius 200 filler to produce a radius 200 filler in the condition as formed in 206. In some instances, the radius 200 filler can be mounted in a symmetrical form 212 (Figure 6) in a condition of as stacked 204, which can be formed in a symmetrical form 212 in a condition of as formed 206, such as by applying heat 308 and / or pressure 306 to the radius filler 200 stacked within a forming matrix 300 as described above with reference to Figures 15-17. In other examples, a radius filler 200 can be mounted in an asymmetrical shape 214 (Figure 27) in a stacked condition 204. In some examples, at least one longitudinal section of a radius filler 200 with an asymmetric shape 214 in condition of how stacked 204 can be formed in an asymmetric shape 214 in a condition of so formed 206, such as using in a forming matrix 300 that has an asymmetric matrix cavity 302 as described above with reference to Figures 28-30, or using any one of a variety of alternative training means.
[00115] When forming the radius filler 200 as stacked in the condition thus formed 206, the method may include forming the filling sides 210 of the opposite radius of the radius filler 200 in a contour that is complementary to the corresponding cavity sides 144 of the cavity partial 142 (Figures 3-4) extending along the longitudinal direction 202 of the composite structure 118. For example, each of the radius 210 filling sides can be formed in a radius that substantially corresponds to the radius of the sides
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46/53 cavity 144.
[00116] In addition, the disclosure comprises modalities according to the following clauses:
[00117] Clause 1. Filling of the composite ray, which comprises:
[00118] a base portion formed by composite layers varying in total width along a global longitudinal direction and defining a variable cross-sectional shape of the base portion along the longitudinal direction, the base portion including at least one zone of transition with a transition start and a transition end along the longitudinal direction;
[00119] the composite layers of the base portion are arranged in one or more stacks, at least one of the one or more stacks comprising a laminated load of composite layers having a predetermined angular fiber orientation sequence and having a stack width, a stack width of at least one of the cells changing within the transition zone; and [00120] a tip portion consisting of a plurality of composite layers formed in a generally triangular shape of cross section and stacked on top of the base portion.
[00121] Clause 2. Fill radius of Clause 1, where: [00122] The composite layers in the tip portion are pulped unidirectional cut ribbon cables.
[00123] Clause 3. Filling radius according to any one of Clauses 1-2, in which:
[00124] the radius filler has a symmetrical shape in a stacked condition.
[00125] Clause 4. Filling radius according to any of Clauses 1-3, in which:
[00126] the radius filler has an asymmetrical shape in a
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47/53 condition as stacked.
[00127] Clause 5. Radius filling in accordance with any of Clauses 1-4, in which:
[00128] at least one of the one or more stacks has a sequence of fiber orientation angles comprising a layer of degree + non-zero, a layer of non-zero degree and a layer of 0 degrees between the layer of degree + non-zero and the non-zero degree layer; and [00129] the absolute values of a fiber orientation angle of the degree + non-zero layer and of the degree-non-zero layer being equal.
[00130] Clause 6. Closing radius of Clause 5, where: [00131] the sequence of the angle of orientation of the fibers of at least one of the one or more stacks comprising a layer of +30 degrees, a layer of -30 degrees and a 0 degree layer between the +30 degree layer and the -30 degree layer.
[00132] Clause 7. Radius filling in accordance with any of Clauses 5-6, in which:
[00133] in at least one of the stacks, the 0 degree layer ends at a layer termination and results in at least one longitudinal portion of the pile comprising the degree + nonzero layer and the degree - non-zero layer in contact with back to back to each other.
[00134] Clause 8. Fill radius of Clause 7, in which the layer termination of the 0 degree layer is located in one of the following: at the beginning of the transition; within the transition zone; and, at the end of transition.
[00135] Clause 9. Filling radius according to any of Clauses 1-8, in which:
[00136] the radius filler is configured to be installed
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48/53 in a partial cavity of a composite structure and in a condition of assembly in the cavity of the part, the partial cavity being a cavity base;
[00137] the tip portion having a bottom surface of the tip portion;
[00138] the base portion having a bottom surface of the base portion and a height of the base portion;
[00139] the base portion providing the radius filler with a vertical overflow of the partial cavity where: [00140] a height of the base portion as stacked from the radius filler in the condition as stacked is at least 5 percent greater than a height of the base portion, depending on the assembly, of the radius filling in the assembled condition; and [00141] the height of the stacked base portion is at least an additional layer thickness in addition to the height of the base portion as mounted;
[00142] the height of the base portion as stacked that extends from the bottom surface of the base part to the bottom surface of the tip part of the radius filler in the condition as stacked; and [00143] the height of the base portion as mounted from the base of the cavity to the location of the bottom surface of the tip portion if the tip portion is in the cavity of the portion in the condition as mounted.
[00144] Clause 10. Filling radius of Clause 9, where: [00145] the partial cavity has opposite sides of the cavity respectively defined by opposite outer rays of the composite structure; [00146] the base portion including a single bottom stack and a plurality of medium stacks each having a stack width; and
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49/53 [00147] the stack width of all medium stacks is substantially equivalent to a partial cavity width at an intersection of the sides of the cavity with a median plane of the respective average stack.
[00148] Clause 11. Composite structure, comprising:
[00149] a pair of composite charges in contact back to back with each other and forming a longitudinal cavity;
[00150] a radius filler installed in the part cavity and including:
[00151] a base portion formed by composite layers varying in total width along an overall longitudinal direction and defining a variable cross-sectional shape of the base portion along the longitudinal direction, the base portion including at least one zone of transition with a transition start and a transition end along the longitudinal direction;
[00152] the composite layers of the base portion are arranged in one or more stacks, at least one of the one or more stacks comprising a laminated load of composite layers having a predetermined angular fiber orientation sequence and having a stack width, a stack width of at least one of the cells changing within the transition zone; and [00153] a tip portion consisting of a plurality of composite layers formed in a generally triangular shape of cross section and stacked on top of the base portion.
[00154] Clause 12. Method of manufacturing a radius filler, comprising the steps of:
[00155] providing a base portion formed by composite layers that vary in total width over at least a portion of an overall longitudinal direction and that define a variable cross-sectional shape of the base portion along the lonPetition direction 870170070807, from 9/21/2017, p. 56/239
50/53 gitudinal, including the base portion with at least one transition zone having a transition start and a transition end along the longitudinal direction, the composite layers of the base portion being arranged in at least one or more stacks one of one or more stacks comprising a laminated composite layer load having a predetermined fiber orientation angle sequence and having a stack width, the stack width of at least one of the stacks changing within the transition zone;
[00156] providing a tip portion with a generally triangular shape of cross section;
[00157] stack the tip portion over the base portion to form a radius filler in a stacked condition; and [00158] applying at least one of the heat and pressure to the radius filler to produce a radius filler on condition that it is formed with a variable cross-sectional shape.
[00159] Clause 13. Method of Clause 12, in which the step of supplying the tip portion comprises:
[00160] pultrusion of a plurality of unidirectional cut ribbon cables in generally triangular shape in cross section. [00161] Clause 14. Method in accordance with any of Clauses 12-13, further including:
[00162] formation of the radius filler in a symmetrical form in a condition as stacked.
[00163] Clause 15. Method in accordance with any of Clauses 12-14, further including:
[00164] formation of the ray filler in an asymmetric form in a condition of as stacked.
[00165] Clause 16. Method according to any of Clauses 12-15, in which the step of supplying the base portion
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51/53 includes:
[00166] supplying at least one stack of the base portion as a laminated load comprising a grade + non-zero layer, a non-zero grade layer and a 0 degree layer between the grade + non-zero layer and the non-zero degree layer, the absolute values of a fiber orientation angle of the non-zero degree + layer and the non-zero degree layer being equal.
[00167] Clause 17. Method of Clause 16, wherein the step of supplying at least one stack of the base portion as a laminated filler includes:
[00168] supplying at least one stack of the base portion as a laminated filler comprising a +30 degree layer, a -30 degree layer and a 0 degree layer between the +30 degree layer and the -30 layer degrees.
[00169] Clause 18. Method in accordance with any of Clauses 16-17, further including:
[00170] termination, in at least one of the stacks, of the 0 degree layer at a termination of the layer located within a total length of the radius filler, so that in at least one longitudinal section of the radius filler, the cell comprising the non-zero degree + layer and the non-zero degree layer in back to back contact with each other.
[00171] Clause 19. Method of Clause 18, in which the step of finishing the 0 degree layer comprises locating the finishing of the layer in one of the following: at the beginning of the transition; within the transition zone; and at the end of the transition.
[00172] Clause 20. Method according to any one of Clauses 12-19, in which the radius filler is configured to be installed in a partial cavity of a composite structure and in a condition mounted inside the partial cavity, the caviPetition being 870170070807, of 9/21/2017, p. 58/239
52/53 a cavity base, the tip portion having a lower surface of the tip portion, the base portion having a lower surface of the base portion and a height of the base portion, the method further including:
[00173] formation of the radius filling with a vertical filling in excess of the partial cavity in which:
[00174] a height of the base portion as stacked of the lightning filler in the condition as stacked is at least 5 percent greater than a height of the base portion, as per the assembly, of the lightning filler in the condition of assembled; and [00175] the height of the stacked base portion is at least an additional layer thickness in addition to the height of the assembled base portion;
[00176] the height of the stacked base portion extending from the bottom surface of the base part to the bottom surface of the tip portion of the radius filler in the condition as stacked; and [00177] the height of the base portion assembled from the base of the cavity to the location of the bottom surface of the tip portion, if the tip portion is in the cavity of the piece in the assembled condition. [00178] Clause 21. Method of Clause 20, in which the partial cavity has sides of the opposite cavity, respectively, defined by opposite outer rays of the composite structure, the method also including:
[00179] formation of the base portion from a single bottom stack and a plurality of medium stacks each having a stack width; and [00180] forming the radius filler in a stacked condition such that the stack width of all medium stacks is substantially equivalent to a partial cavity width
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53/53 at an intersection on one side of the cavity with a median plane of the respective intermediate stack.
[00181] Clause 22. Method of Clause 21, in which:
[00182] the bottom stack has a bottom stack width that is less than the width of the partial cavity at a bottom part of the bottom of the cavity.
[00183] Many modifications and other configurations of the disclosure will have in mind for a specialist in the technique, to which this disclosure belongs, the benefit of the teachings presented in the previous descriptions and in the associated drawings. The configurations described here must be illustrative and are not intended to be limiting or exhaustive. Although specific terms are used here, they are used only in a generic and descriptive sense and not for the purpose of limitation.
Petition 870170070807, of 9/21/2017, p. 60/239
1/6

权利要求:
Claims (15)
[1]
1. Composite ray filling (200) characterized by the fact that it comprises:
a base portion (238) formed by composite layers (258) varying in total width along a global longitudinal direction (202) and defining a variable cross-sectional shape of the base portion (238) along the longitudinal direction (202 ), including the base portion (238) with at least one transition zone (294) with a transition start (296) and a transition end (298) along the longitudinal direction (202);
the composite layers (258) of the base portion (238) are arranged in one or more stacks (250), at least one of the one or more stacks (250) comprising a laminated load (178) of composite layers (258) having a angular sequence of fiber orientation (262) predetermined and having a stack width (278, 282), the stack width of at least one of the stacks (250) changing within the transition zone (294); and a tip portion (220) consisting of a plurality of composite layers (258) formed in a generally triangular shape of cross section and stacked on top of the base portion (238).
[2]
2. Radius filling (200), according to claim 1, characterized by the fact that:
the composite layers (258) at the tip portion (220) are pulped unidirectional cut ribbon cables (222).
[3]
3. Radius filling (200) according to any one of claims 1 to 2, characterized in that:
the radius filler (200) has a symmetrical shape (212) in a stacked condition (206)
[4]
4. Radius fill (200) according to any
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2/6 of claims 1 to 3, characterized by the fact that:
the radius filler (200) having an asymmetrical shape (214) in a condition as stacked (206)
[5]
5. Radius filling (200) according to any one of claims 1 to 4, characterized in that:
at least one of the one or more stacks (250) having a sequence of fiber orientation angles (262) comprising a grade + nonzero layer (266), a grade - nonzero layer (270) and a layer 0 degrees (264) between the degree + non-zero layer (266) and the non-zero degree layer (270); and the absolute values of a fiber orientation angle (262) of the degree + non-zero layer (266) and of the non-zero degree layer (270) being equal.
[6]
6. Radius filling (200) according to claim 5, characterized by the fact that:
the sequence of the fiber orientation angle (262) of the at least one of the one or more stacks (250) comprises a +30 degree layer (268), a -30 degree layer (272) and a 0 degree layer ( 264) between the +30 degree layer (268) and the -30 degree layer (272).
[7]
7. Radius filling (200) according to any one of claims 5 to 6, characterized by the fact that:
in at least one of the stacks (250) the 0-degree layer (264) terminates at a layer termination (274) and results in at least a longitudinal portion of the stack comprising the non-zero degree + layer (266) and the non-zero grade layer (270) in back to back contact with each other.
[8]
8. Radius filler (200) according to any one of claims 1 to 7, characterized in that the radius filler (200) is configured to be installed 870170070807, from 9/21/2017, pg. 62/239
3/6 side in a partial cavity (142) of a composite structure (118) and in an assembled condition (206) in the cavity of the part (142), the partial cavity (142) having a cavity base (146);
the tip portion (220) having a lower surface (228) of the tip portion;
the base portion (238) having a bottom surface of the base portion (246) and a height of the base portion (243);
the base portion (238) providing the radius filler (200) with an excess vertical filler (248) of the partial cavity (142) in which:
a height of the base portion (242) as stacked from the radius filler (200) in the condition as stacked (206) is at least 5 percent greater than a height of the base portion (243), depending on the assembly, of the radius filling (200) in the condition as mounted; and the height of the stacked base portion (242) is at least an additional thickness of the layer in addition to the height of the base portion as (243) as mounted;
the height of the base portion as stacked (242) extending from the bottom surface of the base portion (246) to the bottom surface of the tip portion (228) of the radius filler (200) in the condition as stacked ( 206); and the height of the base portion as mounted (243) extending from the base of the cavity (146) to the location of the lower surface (228) of the tip part, if the tip portion (220) is in the cavity of the part ( 142) on condition that as mounted (206).
[9]
9. Radius filling (200) according to claim
8, characterized by the fact that:
the partial cavity (142) has opposite sides of the cavity
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4/6 (144) respectively defined by opposite outer radii (140) of the composite structure (118);
the base portion (238) including a single bottom stack (276) and a plurality of medium stacks (280) each having a stack width (278, 282); and the stack width (278, 282) of all medium stacks (280) is substantially equivalent to a partial cavity width (142) at an intersection (285) of the sides of the cavity (144) with a median plane (284) of the respective medium stack (280).
[10]
10. Method of manufacturing a radius filler (200), characterized by the fact that it comprises the steps of:
providing a base portion (238) formed of composite layers (258) that vary in total width over at least a portion of an overall longitudinal direction (202) and that define a variable cross-sectional shape of the base portion (238 ) along the longitudinal direction (202), including the base portion (238) with at least one transition zone (294) which has a transition start (296) and a transition end (298) along the longitudinal direction ( 202), the composite layers (258) of the base portion (238) being arranged in one or more stacks (250), at least one of the one or more stacks (250) comprising a laminated filler (178) of composite layers (258 ) with a predetermined fiber orientation angle sequence (262) and having a stack width, (278, 282) the stack width (278, 282) of at least one of the stacks (250) changing within the transition zone (294) providing a tip portion (220) with a general shape triangular cross-section;
stacking the tip portion (220) on the base portion (238) to form a radius filler (200) in a stacked condition (206); and
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5 / Q apply at least one of heat (308) and pressure (306) to the radius filler (200) to produce a radius filler (200) in the condition as formed with a variable cross-sectional shape.
[11]
11. Method according to claim 10, characterized in that the step of supplying the tip portion (220) comprises:
pultrusion of a plurality of unidirectional cut ribbon cables (222) in generally triangular shape in cross section.
[12]
12. Method according to any one of claims 10 to 11, characterized by the fact that it also includes:
forming the radius filler (200) in a symmetrical shape (212) in a stacked condition (206).
[13]
13. Method according to any of claims 10 to 12, characterized by the fact that it also includes:
forming the radius filler (200) in an asymmetrical shape (214) in a stacked condition (206).
[14]
Method according to any one of claims 12 to 13, characterized in that the step of supplying the base portion (238) includes:
providing at least one stack (250) of the base portion (238) as a laminated filler (178) comprising a non-zero grade layer (266), a non-zero grade layer (270) and a 0 layer degrees (264) between the degree + non-zero layer (266) and the non-zero degree layer (270), the absolute values of a fiber orientation angle (262) of the degree + non-zero layer (266) and the non-zero degree layer (270) being the same.
[15]
15. Method according to any one of claims 10 to 14, characterized in that the step of supplying at least one battery of the base portion (238) as a lamiPetição charge 870170070807, of 9/21/2017, p. 65/239
6/6 nothing (178) include:
supply at least one stack of the base portion (238) as a laminated filler (178) comprising a +30 degree layer (268), a -30 degree layer (272) and a 0 degree layer (264) between the +30 degree layer (268) and the -30 degree layer (272).
Petition 870170070807, of 9/21/2017, p. 66/239
1/23
106

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法律状态:
2018-05-02| B03A| Publication of a patent application or of a certificate of addition of invention [chapter 3.1 patent gazette]|

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2021-09-08| B06W| Patent application suspended after preliminary examination (for patents with searches from other patent authorities) chapter 6.23 patent gazette]|

优先权:

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申请号 | 申请日 | 专利标题

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US15/282,616|2016-09-30|

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US15/282,616|US10046525B2|2016-09-30|2016-09-30|Advanced variable radius laminated composite radius filler|

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