초록

A composite structure having a base charge and an outer channel charge is provided. The outer channel charge has an inner radius and an outer radius. A charge of plies adjacent to the inner radius reduces the inner radius.

대표청구항 ▼

1. A composite structure comprising: an outer channel charge and an inner channel charge, each having a vertical web portion transitioning to a horizontal flange, and each having an inner radius and an outer radius;a radius filler region formed at an intersection of the inner radii of the outer chan

1. A composite structure comprising: an outer channel charge and an inner channel charge, each having a vertical web portion transitioning to a horizontal flange, and each having an inner radius and an outer radius;a radius filler region formed at an intersection of the inner radii of the outer channel charge and the inner channel charge, the radius filler region having a generally triangular shape and filled with a radius filler;a base charge joined on one side to outer surfaces of the horizontal flanges of the outer channel charge and the inner channel charge, the base charge having a base side local material positioned along a length of a base side of the radius filler region and positioned outside of the radius filler region; anda charge of plies having a radial side local material positioned along each side of the inner radii of the outer channel charge and the inner channel charge, that reduce the inner radii,the outer channel charge and the inner channel charge, the radius filler region, the base charge, and the charge of plies, all forming the composite structure. 2. The structure of claim 1, wherein the charge of plies comprises continuous plies comprising one of, individually interspersed continuous plies and stacked composite continuous plies. 3. The structure of claim 1, further comprising a segmented interlaminate radius filler having interlaminar filler segments between the charge of plies to space the charge of plies away from each other to create a T-section radius. 4. The structure of claim 3, wherein the interlaminar filler segments comprise chopped fibers, tape plies including unidirectional tape, fabric plies, fiberglass, continuous plies, metallic pieces, or a combination of two or more of the chopped fibers, the tape plies including unidirectional tape, the fabric plies, the fiberglass, the continuous plies, and the metallic pieces. 5. The structure of claim 1, wherein the base charge comprises a reduced base charge further comprising base charge local composite plies positioned along an interface of the base charge and the base side local material. 6. The structure of claim 1, further comprising multiple pockets of ply charges interleaved throughout or adjacent the inner radii of the outer channel charge and the inner channel charge, that reduce the inner radii. 7. The structure of claim 1, further comprising a full ply fabric and adhesive inner wrap applied between the base charge and the outer channel charge, between the base charge and the inner channel charge, between the base charge and the base side of the radius filler region, and applied adjacent to the inner radii to further reduce the inner radii. 8. The structure of claim 1, wherein the outer channel charge comprises a composite stiffener having a C-shaped cross-section. 9. The structure of claim 1, wherein the composite structure comprises an aircraft composite structure. 10. An aircraft comprising: a fuselage;at least one wing coupled to the fuselage, the at least one wing having a composite structure comprising: an outer channel charge and an inner channel charge, each having a vertical web portion transitioning to a horizontal flange, and each having an inner radius and an outer radius;a radius filler region formed at an intersection of the inner radii of the outer channel charge and the inner channel charge, the radius filler region having a generally triangular shape and filled with a radius filler;a base charge joined on one side to outer surfaces of the horizontal flanges of the outer channel charge and the inner channel charge, the base charge having a base side local material positioned along a length of a base side of the radius filler region and positioned outside of the radius filler region; anda charge of plies having a radial side local material positioned along each side of the inner radii of the outer channel charge and the inner channel charge, that reduce the inner radii,the outer channel charge and the inner channel charge, the radius filler region, the base charge, and the charge of plies, all forming the composite structure. 11. The aircraft of claim 10, wherein the charge of plies comprises continuous plies comprising one of, individually interspersed continuous plies and stacked composite continuous plies. 12. The aircraft of claim 10, further comprising a segmented interlaminate radius filler having interlaminar filler segments between the charge of plies to space the charge of plies away from each other to create a T-section radius. 13. The aircraft of claim 10, wherein the base charge comprises a reduced base charge further comprising base charge local composite plies positioned along an interface of the base charge and the base side local material. 14. The aircraft of claim 10, further comprising multiple pockets of ply charges interleaved throughout or adjacent to the inner radii of the outer channel charge and the inner channel charge, that reduce the inner radii. 15. A method for forming a composite structure having a reduced area radius filler, the method comprising the steps of: forming an outer channel charge and an inner channel charge, each having a vertical web portion transitioning to a horizontal flange portion, and each having an inner radius and an outer radius;forming a radius filler region at an intersection of the inner radii of the outer channel charge and the inner channel charge, the radius filler region having a generally triangular shape;joining the horizontal flange portions of the outer channel charge and the inner channel charge to one side of a base charge, the base charge having a base side local material positioned along a length of a base side of the radius filler region and positioned outside of the radius filler region;adding a charge of plies having a radial side local material positioned along each side of the inner radii of the outer channel charge and the inner channel charge, to reduce the inner radii;coupling to the radius filler region a radius filler having radii that substantially correspond to the reduced inner radii; and,forming the composite structure having the reduced area radius filler, with the outer channel charge and the inner channel charge, the radius filler region, the base charge, and the charge of plies. 16. The method of claim 15, wherein the step of adding the charge of plies adjacent to the inner radii to reduce the inner radii comprises forming the charge of plies as continuous plies comprising one of, individually interspersed continuous plies and stacked composite continuous plies. 17. The method of claim 15, further comprising the step of using a segmented interlaminate radius filler having interlaminar filler segments between the charge of plies to space the charge of plies away from each other to create a T-section radius. 18. The method of claim 15, further comprising the step prior to forming the composite structure, the step of adding base charge local composite plies to the base charge, the base charge local composite plies positioned along an interface of the base charge and the base side local material, that further reduce the inner radii. 19. The method of claim 15, wherein the step of adding the charge of plies adjacent to the inner radii to reduce the inner radii comprises interleaving multiple pockets of ply charges throughout or adjacent the inner radii of the outer channel charge and the inner channel charge, that reduce the inner radii. 20. The method of claim 15, further comprising the step prior to forming the composite structure, the step of applying a full ply fabric and adhesive inner wrap between the base charge and the outer channel charge, between the base charge and the inner channel charge, between the base charge and the base side of the radius filler region, and applying adjacent to the inner radii to further reduce the inner radii.