Variable-radius laminated radius filler and system and method for manufacturing same
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-005/12
B32B-003/08
B26D-001/00
B32B-037/14
B29C-070/54
B29C-070/34
B29D-099/00
출원번호
US-0705800
(2012-12-05)
등록번호
US-9327470
(2016-05-03)
발명자
/ 주소
Krajca, Scott Edward
Sweetin, Joseph L.
Harris, Christopher G.
Kline, William T.
Forston, Gabriel Z.
출원인 / 주소
The Boeing Company
인용정보
피인용 횟수 :
3인용 특허 :
4
초록▼
A variable-radius laminated composite radius filler may include a base portion, a keyway portion, and a tip portion. The base portion may be formed of a plurality of variable width composite plies defining a variable cross-sectional shape of the base portion. The keyway portion may be stacked on the
A variable-radius laminated composite radius filler may include a base portion, a keyway portion, and a tip portion. The base portion may be formed of a plurality of variable width composite plies defining a variable cross-sectional shape of the base portion. The keyway portion may be stacked on the base portion and may be formed of a plurality of substantially constant width composite plies defining a substantially constant cross-sectional shape of the keyway portion. The tip portion may be stacked on the keyway portion and may be formed of composite plies.
대표청구항▼
1. A variable-radius laminated composite radius filler, comprising: a base portion formed of a plurality of variable width composite plies varying in overall width along an overall lengthwise direction and defining a variable cross-sectional shape of the base portion, the variable cross-sectional sh
1. A variable-radius laminated composite radius filler, comprising: a base portion formed of a plurality of variable width composite plies varying in overall width along an overall lengthwise direction and defining a variable cross-sectional shape of the base portion, the variable cross-sectional shape varying along the lengthwise direction, the length being longer than the width, the base portion includes one or more transition zones, each transition zone including:a plurality of composite plies changing width;a first composite ply changing in ply width within the transition zone along with a change in ply width of a second composite ply within the same transition zone;the change in ply width of the first composite ply has a first taper extending from the lengthwise edge of the start of the transition zone to the lengthwise edge of the end of the transition zone;the change in ply width of the second composite ply has a second taper extending from the lengthwise edge of the start of the transition zone to the lengthwise edge of the end of the transition zone;the angles of the first and second taper being substantially the same;at least one of a keyway portion and a tip portion stacked on top of the base portion;the keyway portion stacked on the base portion and being formed of a plurality of constant width composite plies defining a constant cross-sectional shape of the keyway portion, the constant cross-sectional shape being constant along the lengthwise direction; andthe tip portion stacked on the base portion or the keyway portion and being formed of composite plies. 2. The radius filler of claim 1, wherein: at least one of the base portion and the keyway portion has a stepped pyramidal cross-sectional shape. 3. The radius filler of claim 1, wherein: at least one of the keyway portion and the base portion is formed as a stack of layers; andeach one of the layers comprises a laminated charge containing a plurality of composite plies. 4. The radius filler of claim 3, wherein: each laminated charge in the keyway portion and the base portion is similar to one another and containing alternating +45 degree and −45 degree composite plies sandwiched between 0 degree composite plies on opposite sides of the 45 degree composite plies. 5. The radius filler of claim 1, wherein: the transition zone comprises a change in at least one of a base portion width and a base portion height in correspondence with at least one of a ply drop and a ply addition in a composite structure. 6. The radius filler of claim 5, wherein: the transition zone is offset from the at least one of the ply drop and the ply addition. 7. The radius filler of claim 5, wherein: the base portion is comprised of a top layer, a bottom layer, and one or more mid layers located between the top layer and the bottom layer; andthe change in the base portion height comprises a termination of one of the mid layers. 8. The radius filler of claim 7, wherein: a terminating end of one of the mid layers has a non-square shape. 9. The radius filler of claim 7, wherein: the top layer is continuous along the lengthwise direction of the base portion. 10. The radius filler of claim 1, wherein: the base portion, the keyway portion and the tip portion comprise a radius filler stack; andthe radius filler stack being formed into a final radius filler having opposing radius filler sides that are contoured complementary to stiffener outside radii of a composite structure. 11. The radius filler of claim 10, wherein: the composite structure has a stiffener inner radius that is constant along the lengthwise direction. 12. The radius filler of claim 1, wherein: the tip portion has a constant cross-sectional area and a variable cross-sectional shape. 13. The radius filler of claim 5, wherein: the base portion is comprised of a top layer, a bottom layer, and one or more mid layers located between the top layer and the bottom layer; andthe change in the base portion height comprises a termination of a top layer. 14. The radius filler of claim 1, wherein: the radius filler has a variable-radius along a lengthwise direction. 15. The radius filler of claim 1, wherein: the keyway portion contains approximately 8 to 20 composite plies. 16. The radius filler of claim 1, wherein: the base portion contains approximately 20 to 52 composite plies. 17. The radius filler of claim 1, wherein: the keyway portion has as a keyway portion width of less than approximately 0.25 inch. 18. The radius filler of claim 1, wherein: the radius filler has opposing sides contoured complementary to a radius filler region of a composite structure;the base portion is configured such that opposing sides are configured complementary to a corresponding pair of stiffener outside radii of a pair of stiffeners defining a radius filler region along a lengthwise direction of the composite structure. 19. The radius filler of claim 1, wherein: the composite plies are carbon-fiber-reinforced pre-preg plies. 20. The radius filler of claim 1, wherein: the composite plies of the tip portion comprise a plurality of substantially constant width composite plies. 21. The radius filler of claim 1, wherein: the tip portion is formed of three composite plies. 22. The radius filler of claim 1, wherein: the composite plies of the tip portion are each approximately 0.25 inch wide. 23. The radius filler of claim 1, wherein: the composite plies of the tip portion are carbon fiber reinforced plastic tape. 24. The radius filler of claim 1, wherein: the composite plies of the tip portion have a thickness of approximately 0.0075 inch. 25. The radius filler of claim 1, wherein: the tip portion has a maximum tip portion width of approximately 0.25 inch. 26. The radius filler of claim 1, wherein: the tip portion has a tip portion height of approximately 0.023 inch. 27. The radius filler of claim 1, wherein: the tip portion has a triangular cross-sectional shape. 28. The radius filler of claim 1, wherein: the tip portion has a variable cross-sectional shape. 29. The radius filler of claim 28, wherein: the tip portion has a width tip portion width that varies in correspondence with radii of a radius filler region of a composite structure. 30. The radius filler of claim 1, wherein: the keyway portion has angled sides and defines a trapezoidal shape. 31. The radius filler of claim 1, wherein: the keyway portion has a keyway portion height that is constant along a lengthwise direction. 32. The radius filler of claim 1, wherein: the keyway portion has a maximum width of less than approximately 0.25 inch. 33. The radius filler of claim 1, wherein: the tip portion and the keyway portion are formed as a unitary upper portion. 34. The radius filler of claim 3, wherein: the layers in the keyway portion are manufactured from a laminated charge having the same composite material as the remaining layers of the keyway portion. 35. The radius filler of claim 7, wherein: the top layer overlaps a terminating end of a mid layer. 36. The radius filler of claim 7, wherein: the top layer has a stair-step shape formed by terminating ends of one or more mid layers. 37. The radius filler of claim 7, wherein: the top layer has a top layer width that varies with at least one of ply drops and ply additions in a composite structure. 38. The radius filler of claim 8, wherein: the terminating end of a mid layer has a generally pointed shape. 39. The radius filler of claim 8, wherein: the terminating end of a mid layer has a generally rounded shape. 40. The radius filler of claim 1, wherein: the base portion includes one or more constant zones comprising regions wherein the base portion has a relatively constant cross-sectional shape; andthe constant zones being separated by transition zones. 41. The radius filler of claim 6, wherein: the transition zones are offset from the start of ply drops and ply additions by a distance of approximately 0.10-0.50 inch.
Charles, Jordan; Sampedro-Thompson, William M.; Watkins, Jessica L.; Roache, Ryan Christopher; Gamble, Michael John; Downey, Tyler W.; Choy, Wendell C. K.; Santini, Gregory M., Laminate composite wing structures.
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