Recycled resin infusion radius filler and method

Abstract

The present application relates to recycled resin infusion radius fillers and methods. Disclosed herein are customizable composite longitudinal radius fillers made from harvested recycled dry fiber material, composite components, longitudinal radius filler cavities filled with customizable composite longitudinal radius fillers, and methods of manufacture.

Description

Technical Field

[0001] This disclosure generally relates to the field of composite packing components. More specifically, this disclosure relates to the field of composite packing components comprising elongated fibers shaped into two or more segments along their length. Background Technology

[0002] Composite material structures are widely used due to their high strength-to-weight ratio, corrosion resistance, and other advantageous properties. In aircraft manufacturing, composite materials are increasingly used to form fuselages, wings, horizontal and vertical stabilizers, and other components. For example, aircraft wings can be formed from composite skin panels co-cured or co-bonded with internal composite structures such as composite stringers. Composite stringers can extend along the wingspan from the wing root to the wingtip.

[0003] Composite materials are strong, lightweight materials made by combining two or more functional components. For example, a composite material may include reinforcing fibers defined within a polymer resin matrix. In thermosetting composites, fibers and resin are arranged and cured to form the composite. When composite structural members are joined together, gaps or voids may exist along the bond line between the members due to their geometry. These gaps / voids may need to be filled to increase the strength of the composite assembly. Gap / voids may include inner radii. Composite radius filler members can be applied to fill these gaps / voids. Composite radius filler members can include various shapes to match the gaps and are often referred to as "noodles".

[0004] Unless so explicitly indicated, no statement herein shall be recognized as prior art simply because such statement is included in the Technical Field and / or Background Art sections. Summary of the Invention

[0005] According to this aspect, non-crimped fabrics from previous resin-infused laminate processing are harvested, reshaped, and otherwise recycled into tailored composite radius filler components or “strip fillers” that have endowed and selected properties and material compatibility with composite material components and structures (which may include, for example, stringer fabrication on wings, tails, and fuselage structures of aircraft), which are reinforced by including tailored composite radius filler components.

[0006] This aspect relates to a composite material assembly for an aircraft component, the composite material assembly comprising at least one composite material component member comprising dry fiber material impregnated with an epoxy resin-containing material, wherein the at least one composite material component member comprises a first side of the composite material component member, a second side of the composite material component member, and a longitudinal radius filler cavity defined by the second side of the composite material component member, the longitudinal radius filler cavity comprising a longitudinal cavity radius. The composite material assembly for the aircraft component further comprises a customizable composite longitudinal radius filler positioned within the longitudinal radius filler cavity, wherein the customizable composite longitudinal radius filler comprises a customizable composite longitudinal radius filler radius sized to match the longitudinal cavity radius, and wherein the customizable composite longitudinal radius filler comprises recycled dry fiber material.

[0007] In another aspect of the invention, the recycled dry fiber material in the customizable longitudinal radius filler is substantially the same as the dry fiber material in at least one composite component.

[0008] In another aspect of the invention, the recycled dry fiber material in the customizable longitudinal radius filler is a dry fiber non-crimped fabric material.

[0009] In another aspect of the invention, the composite material component is a curable composite material component, wherein the curable composite material component includes a longitudinal radius filler cavity and a curable customizable composite longitudinal radius filler whose dimensions are designed to completely fill the longitudinal radius filler cavity.

[0010] In another current aspect, the composite material assembly is a cured composite material assembly, wherein the cured composite material assembly includes at least one cured composite material member and a cured custom composite longitudinal radius filler, the cured composite material member including a first stiffness and the cured custom composite longitudinal radius filler including a second stiffness.

[0011] On the other hand, the recycled dry fiber material in the customizable longitudinal radius filler is harvested from waste dry fiber material.

[0012] In another current aspect, the recycled dry fiber non-crimped fabric material in the customizable longitudinal radius filler includes respun recycled dry fiber yarns aligned with the longitudinal axis of the longitudinal radius filler cavity.

[0013] On the other hand, the recycled dry fiber material in the customizable longitudinal radius filler is obtained from shredded segments of dry fiber material.

[0014] In another current aspect, composite material components include a ratio of a first stiffness value to a second stiffness value ranging from about 1:6 to about 6:1.

[0015] In another aspect of the invention, the first stiffness is greater than the second stiffness.

[0016] In another aspect of the invention, the first stiffness is less than the second stiffness.

[0017] On the other hand, the first stiffness value is different from the second stiffness value.

[0018] On the other hand, the first stiffness value is essentially equal to the second stiffness value.

[0019] Another aspect of the invention relates to an aircraft assembly, which may be an aircraft stringer assembly, wherein the aircraft assembly includes a composite material assembly comprising at least one composite material assembly member comprising dry fiber material impregnated with an epoxy resin-containing material, wherein the at least one composite material assembly member includes a first side of the composite material assembly member, a second side of the composite material assembly member, and a longitudinal radius filler cavity defined by the second side of the at least one composite material assembly member, the longitudinal radius filler cavity comprising a longitudinal cavity radius. The composite material assembly for the aircraft assembly further includes a customizable composite longitudinal radius filler positioned within the longitudinal radius filler cavity, wherein the customizable composite longitudinal radius filler includes a customizable composite longitudinal radius filler radius whose dimensions are designed to substantially match the longitudinal cavity radius, and wherein the customizable composite longitudinal radius filler includes recycled dry fiber material.

[0020] Another aspect of the invention relates to an aircraft comprising a composite material assembly, the composite material assembly including at least one composite material assembly member comprising dry fiber material impregnated with an epoxy resin-containing material, wherein the at least one composite material assembly member includes a first side of the composite material assembly member, a second side of the composite material assembly member, and a longitudinal radius filler cavity defined by the second side of the composite material assembly member, the longitudinal radius filler cavity including a longitudinal cavity radius. The composite material assembly for the aircraft assembly further includes a customizable composite longitudinal radius filler, wherein the customizable composite longitudinal radius filler includes a customizable composite longitudinal radius filler radius whose dimensions are designed to substantially match the longitudinal cavity radius, and wherein the customizable composite longitudinal radius filler includes recycled dry fiber material.

[0021] Another aspect of the invention relates to a method for forming a customizable composite longitudinal radius filler, the method comprising: harvesting a certain amount of waste dry fiber material from a separate composite material forming process; forming recycled dry fiber material from the waste dry fiber material; processing the recycled dry fiber material to form a customizable composite radius filler; impregnating the customizable recycled dry fiber material with a resin-containing material to form a curable customizable composite longitudinal radius filler; and curing the curable customizable composite longitudinal radius filler, the cured composite longitudinal radius filler being configured to include a selected stiffness.

[0022] In another current aspect, the method further includes: customizing a curable and tunable composite longitudinal radius filler to form a cured composite longitudinal radius filler, said cured composite longitudinal radius filler comprising a selected stiffness value ranging from about 1:6 to about 6:1.

[0023] In another current aspect, the method further includes: forming dry fiber yarns from waste dry fiber material, and orienting the dry fiber yarns along a longitudinal axis during processing to form customizable composite radius fillers.

[0024] Another aspect of the invention relates to a method for forming a customizable composite longitudinal radius filler, the method comprising: harvesting a quantity of waste dry fiber material from a separate composite material forming process; forming recycled dry fiber material from the waste dry fiber material; processing the recycled dry fiber material to form a customizable composite radius filler; impregnating the customizable recycled dry fiber material with a resin-containing material to form a curable customizable composite longitudinal radius filler; and curing the curable customizable composite longitudinal radius filler, the cured composite longitudinal radius filler being configured to include a selected stiffness.

[0025] Another aspect of the invention relates to a method of manufacturing a customizable composite component including a customizable composite longitudinal radius filler, the method comprising: providing at least one composite component member, the at least one composite component member including a first side and a second side, the composite component member including a longitudinal radius filler cavity defined by the second side of the at least one composite component member including a longitudinal cavity radius, and the at least one composite component member including a first stiffness value, the composite component member including a dry fiber material, the dry fiber material being impregnated with a resin-containing material to form the composite component member. The method further includes: positioning a customizable composite longitudinal radius filler in a longitudinal radius filler cavity to form a customizable composite component, wherein the customizable composite longitudinal radius filler includes recycled dry fiber material, the recycled dry fiber material being impregnated with a resin-containing material to form a customizable composite longitudinal cavity filler, wherein the customizable composite longitudinal radius filler includes a radius filler longitudinal radius configured to match the longitudinal cavity radius, wherein the customizable composite longitudinal radius filler is configured to completely fill the longitudinal radius filler cavity, and wherein the customizable composite longitudinal radius filler includes a second stiffness value, and wherein the recycled dry fiber material includes a custom form of dry fiber material.

[0026] On the other hand, the first stiffness value is equal to the second stiffness value.

[0027] On the other hand, the first stiffness value is essentially equal to the second stiffness value.

[0028] On the other hand, the first stiffness value is different from the second stiffness value.

[0029] On the other hand, the dry fiber material in the composite component and the recycled dry fiber material in the customizable composite longitudinal radius filler are derived from the same dry fiber material starting material.

[0030] In another aspect of the invention, the method further includes: customizing the material composition of the customizable composite longitudinal radius filler to obtain a second stiffness value.

[0031] The features, functions, and advantages already discussed can be realized independently in each aspect or combined in other aspects, and further details can be seen in the following description and figures. Attached Figure Description

[0032] Variations of this disclosure have already been described in general terms; reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and in which:

[0033] Figure 1 It is an illustration of a vehicle in the form of an aircraft, based on current information;

[0034] Figure 2 This is a cross-sectional side view of an aircraft assembly including a longitudinal radius stuffing cavity according to an aspect of the present invention;

[0035] Figure 2A yes Figure 2 Enlarged cross-sectional side view of an aircraft component of the type shown;

[0036] Figure 3 This is a cross-sectional side view of an aircraft assembly according to aspects of the present invention, the aircraft assembly including longitudinal radius packing disposed within a longitudinal radius packing cavity;

[0037] Figure 3A yes Figure 3 Enlarged cross-sectional side view of an aircraft component of the type shown;

[0038] Figure 4A (a) is an illustration of the form of dry fiber material to be recycled according to aspects of the present invention;

[0039] Figure 4A (b) is an illustration of the form of the dry fiber material to be recycled according to aspects of the present invention;

[0040] Figure 4A(c) is a diagram illustrating the recycling of dry fiber material from waste dry fiber material into waste dry fiber material fluff balls as a precursor for recycling dry fiber material in an intermediate recycling step according to an aspect of the invention.

[0041] Figure 4B According to the present invention Figure 4A (c) is a diagram of recycled dry fiber yarn strands made from waste dry fiber material fluff balls.

[0042] Figure 4C This is an illustration of recycled dry fiber material yarn strands spun onto a take-up roller according to aspects of the present invention.

[0043] Figure 4D It is based on the current situation of spinning, such as Figure 4C A magnified partial view of the recycled dry fiber strands on the take-up roller shown;

[0044] Figure 5A This is a partial front view of an adjustable longitudinal radius filler mold for forming a recyclable composite material radius filler according to aspects of the present invention;

[0045] Figure 5B It is located in the present invention Figure 5A A partial front view of adjustable recyclable dry fiber material in a shredded form within an adjustable composite longitudinal radius filler mold, as shown.

[0046] Figure 5C It is from the perspective of the present invention Figure 5A The illustration shows an adjustable recyclable composite longitudinal radius filler made from shredded dry fiber material removed by a mold.

[0047] Figure 5D According to the present invention Figure 5C A perspective view of the type of adjustable recyclable composite longitudinal radius filler shown, illustrating the longitudinal triangular geometric radius filler dimensions, which can be designed to substantially match the longitudinal radius filler cavity in the composite assembly;

[0048] Figure 6A It is located according to aspects of the present invention. Figure 5A A partial front view of the adjustable recycled dry fiber material in the form of respun recycled dry fiber yarn in the adjustable composite longitudinal radius filler mold shown;

[0049] Figure 6B This is an illustration of a respun recycled dry fiber material in the form of a respun recycled dry fiber yarn that has been removed from a mold and formed into a respun recycled dry fiber yarn that is a respun recycled composite longitudinal radius filler according to an aspect of the present invention.

[0050] Figure 6C According to the present invention Figure 6B A perspective view of the type of adjustable recyclable composite longitudinal radius filler shown, illustrating the longitudinal triangular geometric radius filler dimensions, which can be designed to substantially match the longitudinal radius filler cavity in the composite assembly;

[0051] Figure 7A According to aspects of the present invention Figures 5A to 5D A plan view of the appropriate position of the adjustable composite longitudinal radius filler mold and the recycled dry fiber material positioned within the curing bag;

[0052] Figure 7B According to the present invention Figure 7A Side / end view of the position of the type of recycled dry fiber material shown in the adjustable composite longitudinal radius filler curing bag;

[0053] Figure 8 This is a flowchart outlining the current method according to aspects of the present invention;

[0054] Figure 9 This is a flowchart outlining the current method according to aspects of the present invention;

[0055] Figure 10 It is a flowchart outlining the current method according to this aspect; and

[0056] Figure 11 This is a flowchart outlining the current approach based on this aspect. Detailed Implementation

[0057] Composite components that include unavoidable gaps between their jointed and / or formed-together components can have longitudinal or longitudinal gaps or cavities formed along the length of the composite component, which can be filled with radial filler to fill the cavities. According to this aspect, dry fiber material is harvested from other composite forming processes and / or otherwise obtained as waste and is recycled and reformed for use in forming customizable composite longitudinal radial fillers to have intentionally customized properties, because the recycled dry fiber material can be aligned and / or otherwise oriented within the formed radial filler to achieve selected customized properties, including, for example, radial filler stiffness, which can be selected to be equal to or substantially equal to or different from (e.g., greater than or less than) the stiffness of the composite component components surrounding the radial filler. "Dry" fiber refers to fiber that has not been impregnated with resin or other materials and is in a state without perceptible moisture.

[0058] When harvested dry fiber waste is obtained from the manufacturing process of an associated composite component member (which will be combined with the radial filler of the present invention to form a complete composite component having the associated radial filler), the dry fiber material in the radial filler and the surrounding composite component member can result in a significant increase in material compatibility between the component member and the radial filler according to aspects of the present invention. The dry fiber material can be and / or can include, for example, dry fiber non-crimped fabric material from a previous resin-infused laminate assembly process, which would otherwise become waste; and alternatively, according to this aspect, harvesting, reforming, and otherwise recycling into a custom composite longitudinal radial filler or “strip filler” has intentionally imparted and intentionally selected physical properties and intentionally selected material compatibility with surrounding and adjacent composite component members and structures to form, for example, a composite component (which may include, for example, stringer manufacturing on wings, tails, fuselages, etc., structures on aircraft, etc.). Intentionally modifying the radial filler forming process to include the recycling of dry fiber material can increase design flexibility for reinforcing composite components by including custom composite radial fillers to form finished composite components.

[0059] In one example, and according to this aspect, improved overall material handling efficiency and material economy, as well as corresponding cost savings, are achieved by harvesting, reforming, and recycling the same dry fiber material used to form the associated composite structure (in one example, the dry fiber material may be, but is not limited to, non-crimped fabric (NCF)). The recycled dry fiber material is then used to manufacture a radius filler structure, which will be combined with and / or injected into and / or within voids (e.g., longitudinal cavities, etc.) within the associated and surrounding composite structure, with the aim of “filling” the voids to form a radius filler-reinforced composite assembly.

[0060] The recycled material used to form the radius filler can be reformulated and then “customized” or “tuned” to impart selected strength, stiffness and / or other physical properties, such that the stiffness of the radius filler formed from the recycled material can be intentionally configured to have a selected stiffness, which is selected to be greater than or less than or to be substantially equal to and substantially “matched” to the stiffness of the surrounding composite material structure in which the radius filler is inserted.

[0061] The same dry fiber material used to manufacture associated composite structures (which present voids / cavities to be filled by radius fillers) is used as recycled material to manufacture radius fillers or otherwise form radius fillers. That is, waste dry fiber material from waste or “waste” lamellar kits used in the manufacture of other composite structures is intentionally harvested, reshaped, and recycled, and otherwise reused as dry fiber material incorporated into the composite radius fillers of this disclosure. A lamellar kit is the sorting and arrangement of fiber lamellars; effectively placing them in a selected fiber orientation or weaving sequence. According to this aspect, recycled “waste” dry fiber material can be “reordered,” “reoriented,” “realigned,” etc., to form dry fiber material, which is thus “regulated” and / or “customized” to include selected physical properties and / or a set of physical properties that are selectively adjusted and / or selectively and predictably “regulated” and / or selectively and predictably “customized” to achieve selected physical characteristic values ​​and / or value ranges.

[0062] According to this aspect, the adjustable and / or customizable physical property is material stiffness. In one example of the invention, the composite material radius filler of the invention can be customized and / or adjusted during its manufacture to have a resulting stiffness characteristic that substantially matches a composite material structure (including cavities) in which the radius filler is positioned to form a composite material assembly, which may be, for example, an aircraft wing stringer assembly.

[0063] In other examples of the invention, the composite radius filler of the invention can be selectively and predictably customized and / or controlled during its manufacture, at least by realigning and positioning the dry fiber form and dry fiber segments, to impart the resulting radius filler with stiffness characteristics that can be greater than or less than the surrounding composite structure and / or incomplete component (including cavity), the radius filler being positioned in the incomplete component to form a complete composite component, which may be, for example, an aircraft wing stringer assembly, etc.

[0064] In this way, according to aspects of the invention, the overall properties of the resulting composite component (which includes radial fillers within surrounding composite component members or sub-components or component precursors) can be selectively and predictably tuned during manufacturing by tailoring the amount, orientation, form, length, and / or width of recycled dry fiber material during the formation of the composite radial filler, while using harvested and “waste” materials that are the same dry fiber material as: 1) used to manufacture composite structures surrounding longitudinal radial cavities (e.g., voids) to be filled; and 2) also used to manufacture composite longitudinal radial fillers, which are then used to fill the longitudinal radial cavities. Furthermore, the same dry fiber material can be managed, processed, reshaped, or otherwise used as a composite starting material in a composite manufacturing scheme similar to that used to manufacture composite component members surrounding the composite radial filler.

[0065] Figure 1 This is an illustration of a vehicle in the form of an aircraft 10, which includes a fuselage 12, a cockpit 14, wings 16 and a tail assembly 17 (equivalently referred to as a "tail"), wherein the tail assembly includes a vertical stabilizer 17a, a rudder 17b, a horizontal stabilizer 17c and an elevator 17d.

[0066] Figure 2 This is a cross-sectional side view of composite component 20, which can be, for example, an aircraft component within a wing, or a stringer assembly, for example, made of multiple component parts or "members". The component may have more or fewer than two component members, such that... Figure 2 The illustrations shown are non-limiting. For example... Figure 2 As shown, the composite component 20 includes a first composite component member 22, which includes a first side 22a (shown as an "outer surface") and a second side 22b (shown as an "inner surface"). The composite component 20 also includes a second composite component member 24 (joined to the first composite component member 22), which includes a first side 24a (shown as an outer surface) and a second side 24b (shown as an inner surface). The composite component 20 further includes a third composite component member 26 (joined to both the first composite component member 22 and the second composite component member 24), wherein the third composite component member 26 includes a first side 26a (shown as an outer surface) and a second side 26b (shown as an inner surface).

[0067] In one example, in the assembly, a first composite component member 22, a second composite component member 24, and a third composite component member 26 are joined together to form a composite component 20, which, when in the form of, for example, an aircraft wing stringer, has a longitudinal length. Figure 2 As shown, at the joint area where the components (e.g., the first composite component 22, the second composite component 24, and the third composite component 26) are joined, the three joining components (e.g., Figure 2 As shown, the inner surfaces (e.g., the first sides) of the second side 22b of the first composite component, the second side 24b of the second composite component, and the second side 26b of the third composite component together surround a longitudinal radius filler cavity 28, which extends through the length of the composite component 20. Figure 2A yes Figure 2 The image shows an enlarged cross-sectional side view of the composite material assembly 20, and also shows an enlarged view of the longitudinal radius filler cavity 28.

[0068] Figure 3 yes Figure 2 The cross-sectional side view of the composite material assembly 20 shown includes, with Figure 2 The similar numbering shown in the figure has the characteristics of a custom composite longitudinal radius filler 30 (equivalently referred to herein as custom composite longitudinal void filler 30) now present in the composite component 20, and the custom composite longitudinal radius filler 30 is sized to substantially completely fill or otherwise completely occupy the longitudinal radius filler cavity 28. Figure 3A yes Figure 3 The diagram shows an enlarged cross-sectional side view of the composite component 20, and also shows an enlarged view of the longitudinal radius filler cavity 28, which is now substantially completely occupied or otherwise “filled” by the regulated composite longitudinal radius filler 30.

[0069] According to aspects of the invention, current custom-designed composite radius fillers can be sized and used to manufacture resin-injected composite components and structures that use radius fillers to occupy or otherwise “fill” longitudinal voids (e.g., stringer reinforcement structures on aircraft). Furthermore, recycled dry fiber materials (which may also be composite dry fiber non-crimped fabric (NCF) materials) can be in the same dry fiber “form” as the material used in adjacent composite component members (e.g., strips, shredded segments, also referred to herein as “stamp-sized segments” and / or “stamps”, etc.).

[0070] According to this aspect, using the same dry fiber material for both the composite structure to be filled and the radial filler achieves significantly enhanced compatibility (e.g., after curing) between the radial filler and the composite structure (e.g., adjacent composite members forming a composite assembly together with the composite radial filler) throughout the entire composite assembly containing the structure to be filled and the radial filler. That is, when combined, the composite component members (assembled to form the cavity to be filled) and the radial filler in place within the cavity together form the composite assembly described herein.

[0071] Figure 4A (a) is an illustration of the source of waste dry fiber material to be harvested, recycled, reused and reshaped according to aspects of the present invention. Figure 4A (a) shows a dry fiber segment or a dry fiber “stamp” segment 40. Figure 4A (b) shows the source of waste dry fiber material to be harvested, recycled, reused and reshaped in the form of discarded dry fiber material strand bundle 42 according to this aspect.

[0072] According to the present invention, recycled dry fiber waste used to prepare composite longitudinal radius fillers can be reused, such that, for example, in the case of "stamps", the waste as the "source" of recycled dry fiber material can be further processed by subsequent "shredding", or the harvested dry fiber waste can undergo recycling treatment, wherein fiber material from the dry fiber source is extracted from the waste and respun into new segments of dry fiber yarn, for example. Figure 4A (c) shows a respun yarn precursor 44 (in the form of a "fluffy" ball) according to the invention, which comprises extracted dry fiber segments to be respun into dry fiber yarn. Figure 4B This is an enlarged illustration of the extraction of dry fiber segments from waste dry fiber material segments (e.g., harvesting from waste dry fiber material segments).

[0073] Various non-restricted respinning technologies can be used to convert waste dry material fibers together with respinning treatment into at least [amount missing]. Figure 4C and Figure 4D The type of respun dry fiber yarn shown in the figure. Figure 4C A partial view of a respun recycled dry fiber yarn assembly 50 is shown, which includes a take-up spindle 52 that can be rotated to "take up" a section of respun dry fiber yarn 54. Figure 4D This is a partial enlarged view of the dry fiber material yarn 54 on the winding spindle 52.

[0074] As described herein, waste dry fiber material may be in the form of shredded segments (shredded segments are equivalently referred to herein as “stamps”), or another form of waste dry fiber material may be processed into dry fiber material stamp segments and further processed (e.g., further “shredded”) to change the size of the stamp segments with the aim of aligning the segments into a mold for forming the longitudinal radius filler of this composite material containing recycled dry fiber material.

[0075] Figure 5A This is an illustration of a partial view of a composite longitudinal radius filler mold 60 (equivalently referred to herein as a "radius filler mold"), which includes processing features 62 in the form of substantially linear and longitudinally triangular recesses into which recycled dry fiber material is inserted to form or "mold" the currently disclosed composite longitudinal dry fiber radius filler (equivalently referred to herein as a "radius filler") under the presence of heat and pressure. According to the present aspect, the physical properties of the molded radius filler can be selectively customized or selectively "tuned" into the radius filler, which is produced, for example, by supplying modified or reused waste dry fiber material, further selectively aligned into the radius filler mold.

[0076] In one example, such as Figure 5B As shown, before presenting the recycled dry fiber radius filler to the radius filler mold 60, a certain amount of harvested dry fiber material in stamp form or shaped into stamp form can be configured in a substantially longitudinal orientation and slightly compressed as a recycled dry fiber radius filler precursor 64. In another example, the recycled dry fiber radius filler precursor 64 may not maintain its shape and may not be slightly compressed before being presented to the mold.

[0077] like Figure 5C As shown, and according to a current example of the invention, a recycled dry fiber radius filler precursor 64 is introduced into a composite recycled dry fiber material mold (e.g., a composite longitudinal radius filler mold 60) to slightly exceed the size of the processing feature 62 of the composite recycled dry fiber material mold (e.g., a composite longitudinal radius filler mold 60) and otherwise "fill" the processing feature 62 of the composite recycled dry fiber material mold (e.g., a composite longitudinal radius filler mold 60). In one example, in Figure 7A and Figure 7B In the exemplary "bagging" process shown, after applying heat and pressure, recycled composite dry fiber radius filler 66, which can be sized to substantially fill the cavity of the composite component, is removed from the mold, and... Figure 5D It is shown as having a substantially triangular shape along its length (e.g., longitudinally).

[0078] Figure 6A , Figure 6B and Figure 6C The formation of recycled composite dry fiber radius filler is illustrated when the recycled dry fiber radius filler precursor 64 is in the form of a respun recycled dry fiber yarn 54 (the respun recycled dry fiber yarn 54 can be oriented into the form of an aligned respun recycled dry fiber yarn (e.g., a recycled dry fiber yarn radius filler precursor 74)).

[0079] like Figure 6A As shown, before presenting the recycled dry fiber yarn radius filler precursor to the radius filler mold 60, a certain amount of harvested dry fiber material waste in the form of the recycled dry fiber yarn radius filler precursor 74 can be configured in a slightly compressed state to at least temporarily "retain its shape," wherein the fiber strands in the yarn are aligned in a substantially longitudinal orientation for the recycled dry fiber yarn radius filler precursor 74. In another example, the recycled dry fiber yarn radius filler precursor 74 may not retain its shape and may not be slightly compressed before being presented to the mold.

[0080] like Figure 6B As shown, in one example, a recycled dry fiber yarn radius filler precursor 74 is introduced into a composite recycled dry fiber material mold (e.g., a composite longitudinal radius filler mold 60), and may slightly exceed the size of the processing feature 62 of the composite recycled dry fiber material mold (e.g., a composite longitudinal radius filler mold 60) and otherwise "fill" the processing feature 62 of the composite recycled dry fiber material mold (e.g., a composite longitudinal radius filler mold 60). In one example, in Figure 7A and Figure 7B After heat and pressure are applied in the exemplary “bagging” process shown, recycled composite dry fiber radius filler 76, which can be sized to substantially fill the cavity of the composite component, is removed from the mold, and Figure 6C It is shown as having a substantially triangular shape along its length (e.g., longitudinally).

[0081] As described herein, the method for forming a recycled dry fiber radius filler according to the present invention may include a mold of a selected size for forming the radius filler, which may be a selected final size. The recycled dry fiber material may be molded, removed from the mold, and then cured according to a heat and pressure scheme within a vacuum bag apparatus. Alternatively, the recycled dry fiber, still in the mold, may be placed in a vacuum bag and subjected to a heat and pressure “in-mold” curing scheme to cure the recycled dry fiber radius filler.

[0082] Figure 7A A top view of an exemplary “bagging process” 80 is shown, in which a recycled dry fiber radius filler precursor 64 is in a mold (e.g., a composite longitudinal radius filler mold 60), wherein both the mold and the precursor material are contained within a vacuum bag 82. Figure 7B This is a side or end view of the bagging process 80. In the bagging process 80, a recycled dry fiber radius filler precursor can be compressed and / or cured into a recycled composite dry fiber radius filler, which can be removed from a mold and inserted into the composite assembly. In one current example, the recycled dry fiber radius filler precursor can be at least partially cured at this stage, wherein the radius filler undergoes a subsequent additional curing step in situ within the composite assembly.

[0083] In another example, at least partially and / or fully consolidated recycled radius fillers may be co-cured with composite component components. According to this aspect, a "co-curable" material is defined as a material that can be co-cured with another material such that the two co-curable materials will co-cur when exposed to co-curing conditions, such as those conditions (predetermined temperature, pressure, heating / rate, residence time, etc.) applied by a predetermined curing scheme to form a "co-cured" composition.

[0084] This aspect considers, but is not limited to, using recycled NCF harvested from composite material processing waste and reusing it as recycled dry fiber NCF. According to this aspect, the recycled dry fiber NCF can be formed into layers of dry fiber NCF, and then these layers are impregnated with, for example, an epoxy resin-based material to form the composite material radius filler of the present invention. Furthermore, this aspect considers using recycled dry fiber NCF harvested from composite material processing waste and reusing it as recycled dry fiber NCF material. This recycled dry fiber NCF material can be used to form a composite prepreg "sheet," which includes the recycled dry fiber NCF material, impregnated with an epoxy resin-based material to form the composite material radius filler of the present invention. Other dry fiber materials may include dry fiber materials containing carbon fibers, glass fibers, boron fibers, aramid fibers, natural fibers, and combinations thereof.

[0085] Figure 8 , Figure 9 , Figure 10 and Figure 11 This outlines current methods for manufacturing radius fillers from recycled composite dry fiber materials. Figure 8 and Figure 9 ) and a flowchart of a method for manufacturing this composite material assembly including a radius filler made from recycled composite dry fiber material, which is equivalently referred to herein as "customizable composite longitudinal radius filler" ( Figure 10 and Figure 11 ).

[0086] Based on the current situation, Figure 8 A method 800 for forming a customizable composite longitudinal radius filler is outlined, wherein method 800 includes: harvesting a certain amount of waste dry fiber material from a separate composite material forming process 802, and recovering the dry fiber material from the waste dry fiber material forming process 804. Method 800 further includes: processing the recovered dry fiber material 806 to form a customizable composite radius filler, impregnating the customizable recovered dry fiber material with a resin-containing material 808 to form a curable customizable composite longitudinal radius filler, and curing the curable customizable composite longitudinal radius filler 810 to form a partially cured composite longitudinal radius filler configured to include a selected stiffness.

[0087] In another current aspect, method 800 further includes: customizing a curable, tunable composite longitudinal radius filler by orienting recycled dry fiber material to form a cured composite longitudinal radius filler including a selected stiffness. By varying the selected stiffness of the customizable composite longitudinal radius filler, the stiffness ratio of the radius filler to the stiffness of the surrounding composite member (when the radius filler is in place within a radius filler cavity in the composite assembly) can be established in the range of about 1:6 to about 6:1. In one example of the invention, the stiffness of the carbon fibers having epoxy resin formed into the radial filler of the invention can have a stiffness value of about 3 MSi to about 21 MSi. In one current example, empirical data points used for analyzing stiffness assessment and / or stiffness calculation methods can employ ASTM D3039 and ASTM D695, as well as analytical methods including mixture rules and classical lamination theory.

[0088] On another current front, Figure 9 A method 900 for forming a customizable composite longitudinal radius filler is outlined, the method 900 comprising elements of method 800, wherein method 900 further comprises: forming 902 dry fiber material yarns from waste dry fiber material, and orienting 904 the dry fiber material yarns along the longitudinal axis during processing to form a customizable composite radius filler.

[0089] Figure 10This paper outlines another aspect of the invention relating to a method 1000 for manufacturing a customizable composite component including a customizable composite longitudinal radius filler, wherein method 1000 includes: providing 1002 at least one composite component member, wherein the at least one composite component member includes a first side and a second side, and wherein the composite component includes a longitudinal radius filler cavity defined by the second side, and wherein the longitudinal radius filler cavity includes a longitudinal cavity radius, and wherein the at least one composite component member includes a first stiffness value. The composite assembly member includes a dry fiber material impregnated with a resin-containing material to form the composite assembly member. Method 1000 further includes: positioning a customizable composite longitudinal radius filler 1004 in a longitudinal radius filler cavity to form a customizable composite component, and forming 1006 a composite component now including the radius filler, wherein the customizable composite longitudinal radius filler includes recycled dry fiber material impregnated with a resin-containing material to form the customizable composite longitudinal radius filler, wherein the customizable composite longitudinal radius filler includes a radius filler longitudinal radius configured to match the longitudinal cavity radius, wherein the customizable composite longitudinal radius filler is configured to completely fill the longitudinal radius filler cavity, and wherein the customizable composite longitudinal radius filler includes a second stiffness value, and wherein the recycled dry fiber material includes a custom form of the dry fiber material, and wherein the first stiffness value is different from the second stiffness value.

[0090] As described in this article, on the other hand, the dry fiber materials in the composite component components and the recycled dry fiber materials in the customizable composite longitudinal radius fillers are derived from the same dry fiber material starting material.

[0091] Figure 11 Another current method 1100, which includes elements of method 1000, is outlined, wherein method 1100 further includes: customizing 1102 the material composition of a customizable composite longitudinal radius filler to obtain a second stiffness value.

[0092] Figure 8 and Figure 9 The currently disclosed methods outlined in this paper can achieve the methods described herein and at least in [the context of the paper]. Figure 3 , Figure 3A , Figure 5B , Figure 5C , Figure 5D , Figure 6A , Figure 6B , Figure 6C , Figure 7A and Figure 7B The radius of the filler is shown in the diagram. Furthermore, Figure 10 and 11The methods outlined in this paper can achieve what is disclosed herein and at least in Figure 1 , Figure 2 , Figure 2A , Figure 3 , Figure 3A The composite material component shown in the image.

[0093] This illustration of the aircraft 10 is provided for the purpose of illustrating an environment in which the composite radius filler component of the present invention can be implemented. Figure 1 The illustration of aircraft 10 in the figure does not imply any architectural limitation on the ways in which different illustrative examples can be implemented. For example, aircraft 10 is shown as a commercial airliner. Different illustrative examples can be applied to other types of aircraft, such as private airliners, rotorcraft, unmanned aerial vehicles, manned spacecraft, unmanned spacecraft, manned rotorcraft, unmanned rotorcraft, satellites, rockets, missiles, manned land aircraft, unmanned land aircraft, manned surface and water aircraft, unmanned surface and water aircraft, manned underwater surface aircraft, unmanned underwater surface aircraft, and combinations thereof.

[0094] This application involves the following terms:

[0095] 1. A composite material assembly, the composite material assembly comprising:

[0096] At least one composite component, the at least one composite component comprising a dry fiber material impregnated with an epoxy resin material, the at least one composite component comprising:

[0097] The first side of the composite material component;

[0098] The second side of the composite component;

[0099] A longitudinal radius filler cavity, defined by a second side of the composite component member, the longitudinal radius filler cavity including a longitudinal cavity radius; and

[0100] A customizable composite longitudinal radius filler is positioned within a longitudinal radius filler cavity, the customizable composite longitudinal radius filler comprising a customizable composite longitudinal radius filler radius whose dimensions are designed to match the radius of the longitudinal cavity, the customizable composite longitudinal radius filler comprising recycled dry fiber material impregnated with the epoxy resin-containing material.

[0101] 2. The composite component according to Clause 1, wherein the recycled dry fiber material in the customizable composite longitudinal radius filler is the same as the dry fiber material in the at least one composite component member.

[0102] 3. The composite material assembly according to Clause 1, wherein the composite material assembly is a curable composite material assembly, the curable composite material assembly including a curable customizable composite longitudinal radius filler, the customizable composite longitudinal radius filler being sized to completely fill the longitudinal radius filler cavity.

[0103] 4. The composite material assembly according to Clause 1, wherein the composite material assembly includes a cured composite material assembly comprising:

[0104] At least one cured composite material component, the at least one cured composite material component including a first stiffness; and

[0105] A cured custom composite longitudinal radius filler, wherein the cured custom composite longitudinal radius filler includes a second stiffness.

[0106] 5. The composite material assembly according to Clause 1, wherein the recycled dry fiber material is harvested from waste dry fiber fabric material.

[0107] 6. The composite material assembly according to Clause 1, wherein the recycled dry fiber material is a dry fiber non-crimped fabric material harvested from waste dry fiber non-crimped fabric material.

[0108] 7. The composite material assembly according to Clause 1, wherein the recycled dry fiber material comprises respun recycled fiber yarns aligned with the longitudinal axis of the longitudinal radius filler cavity.

[0109] 8. The composite material assembly according to Clause 1, wherein the recycled dry fiber material is obtained from shredded segments of recycled dry fiber material.

[0110] 9. The composite material assembly according to Clause 4, the composite material assembly further comprising a first stiffness to second stiffness ratio ranging from 1:6 to 6:1.

[0111] 10. The composite material assembly according to Clause 4, wherein the first stiffness is less than the second stiffness.

[0112] 11. The composite material assembly according to Clause 4, wherein the first stiffness is equal to the second stiffness.

[0113] 12. An aircraft assembly comprising a composite material assembly as described in Clause 1.

[0114] 13. An aircraft comprising a composite material assembly as described in Clause 1.

[0115] 14. A method for forming a customizable composite longitudinal radius filler, the method comprising:

[0116] A certain amount of waste dry fiber material is harvested from a separate composite material forming process;

[0117] Recycled dry fiber material is formed from the waste dry fiber material:

[0118] The recycled dry fiber material is processed to form the customizable composite longitudinal radius filler;

[0119] The recycled dry fiber material is impregnated with a resin-containing material to form a curable composite longitudinal radius filler; and

[0120] The curable composite longitudinal radius filler is cured to form a cured composite longitudinal radius filler, the cured composite longitudinal radius filler being configured to include a selected stiffness.

[0121] 15. The method according to Clause 14, further comprising:

[0122] Forming dry fiber yarn from the waste dry fiber material; and

[0123] During processing, the dry fiber material yarns are oriented along the longitudinal axis to form the customizable composite radius filler.

[0124] 16. The method according to Clause 14, wherein the recycled dry fiber material is a recycled dry fiber non-crimped fabric material.

[0125] 17. A customizable composite longitudinal radius filler, said customizable composite longitudinal radius filler being made according to the method described in Clause 14.

[0126] 18. A method for manufacturing a composite material assembly including a composite longitudinal radius filler, the method comprising:

[0127] Provide at least one composite component member, the at least one composite component member member including a first side of the composite component member member and a second side of the composite component member member, the composite component member member further including a longitudinal radius filler cavity defined by the second side of the composite component member member, the longitudinal radius filler cavity including a longitudinal cavity radius, the at least one composite component member member including a first stiffness value, the composite component member member including a dry fiber material, the dry fiber material being impregnated with a resin-containing material to form the composite component member member;

[0128] A customizable composite longitudinal radius filler is positioned in the longitudinal radius filler cavity to form the composite material assembly. The customizable composite longitudinal radius filler includes recycled dry fiber material, which is impregnated with a resin-containing material to form the customizable composite longitudinal radius filler. The customizable composite longitudinal radius filler includes a longitudinal radius of the filler, which is configured to match the radius of the longitudinal cavity. The customizable composite longitudinal radius filler is configured to completely fill the longitudinal radius filler cavity. The customizable composite longitudinal radius filler includes a second stiffness value.

[0129] Forming the composite material assembly;

[0130] The recycled dry fiber material includes a customized form of the dry fiber material; and

[0131] The stiffness ratio between the first stiffness value and the second stiffness value is in the range of 1:6 to 6:1.

[0132] 19. The method according to Clause 18, wherein the first stiffness value and the second stiffness value are equal.

[0133] 20. The method according to Clause 18, further comprising:

[0134] The material composition of the customizable composite longitudinal radius filler is customized to obtain the second stiffness value.

[0135] According to this aspect, the term "substantially" means that it is not necessary to precisely achieve the stated characteristic, parameter, or value. Instead, deviations or variations, including, for example, tolerances, measurement errors, measurement accuracy limitations, and other factors known to those skilled in the art, may occur in quantities that do not preclude the effect the characteristic is intended to provide. That is, when describing a physical characteristic or value referred to herein as "substantially equivalent," the physical characteristic or value is nearly identical.

[0136] Of course, the aspects presented may be implemented in ways other than those specifically set forth herein without departing from the essential characteristics of this disclosure. This aspect is to be considered illustrative rather than restrictive in all respects, and all variations falling within the meaning and scope of the appended claims are intended to be included therein.

Claims

1. A composite material assembly, the composite material assembly comprising: At least one composite component, the at least one composite component comprising a dry fiber material impregnated with an epoxy resin material, the at least one composite component comprising: The first side of the composite material component; The second side of the composite component; A longitudinal radius filler cavity, defined by a second side of the composite component member, the longitudinal radius filler cavity including a longitudinal cavity radius; and A customizable composite longitudinal radius filler is positioned within a longitudinal radius filler cavity, the customizable composite longitudinal radius filler comprising a customizable composite longitudinal radius filler radius whose dimensions are designed to match the radius of the longitudinal cavity, the customizable composite longitudinal radius filler comprising recycled dry fiber material impregnated with the epoxy resin-containing material.

2. The composite material component according to claim 1, wherein, The recycled dry fiber material in the customizable composite longitudinal radius filler is the same as the dry fiber material in the at least one composite component.

3. The composite material component according to claim 1, wherein, The composite material component is a curable composite material component, which includes a curable customizable composite material longitudinal radius filler, the size of which is designed to completely fill the longitudinal radius filler cavity.

4. The composite material component according to claim 1, wherein, The composite material component includes a cured composite material component, the cured composite material component comprising: At least one cured composite material component, the at least one cured composite material component including a first stiffness; and A cured custom composite longitudinal radius filler, wherein the cured custom composite longitudinal radius filler includes a second stiffness.

5. The composite material component according to claim 1, wherein, The recycled dry fiber material is harvested from waste dry fiber fabric materials.

6. An aircraft assembly comprising the composite material assembly according to claim 1.

7. An aircraft comprising a composite material assembly according to claim 1.

8. A method for forming a customizable composite longitudinal radius filler, the method comprising: A certain amount of waste dry fiber material is harvested from a separate composite material forming process; Recycled dry fiber material is formed from the waste dry fiber material: The recycled dry fiber material is processed to form the customizable composite longitudinal radius filler; The recycled dry fiber material is impregnated with a resin-containing material to form a curable composite longitudinal radius filler; and The curable composite longitudinal radius filler is cured to form a cured composite longitudinal radius filler, the cured composite longitudinal radius filler being configured to include a selected stiffness.

9. A customizable composite longitudinal radius filler, said customizable composite longitudinal radius filler being made according to the method of claim 8.

10. A method for manufacturing a composite material assembly including a composite longitudinal radius filler, the method comprising: Provide at least one composite component member, the at least one composite component member member including a first side of the composite component member member and a second side of the composite component member member, the composite component member member further including a longitudinal radius filler cavity defined by the second side of the composite component member member, the longitudinal radius filler cavity including a longitudinal cavity radius, the at least one composite component member member including a first stiffness value, the composite component member member including a dry fiber material, the dry fiber material being impregnated with a resin-containing material to form the composite component member member; A customizable composite longitudinal radius filler is positioned in the longitudinal radius filler cavity to form the composite material assembly. The customizable composite longitudinal radius filler includes recycled dry fiber material, which is impregnated with a resin-containing material to form the customizable composite longitudinal radius filler. The customizable composite longitudinal radius filler includes a longitudinal radius of the filler, which is configured to match the radius of the longitudinal cavity. The customizable composite longitudinal radius filler is configured to completely fill the longitudinal radius filler cavity. The customizable composite longitudinal radius filler includes a second stiffness value. Forming the composite material assembly; The recycled dry fiber material includes a customized form of the dry fiber material; and The stiffness ratio between the first stiffness value and the second stiffness value is in the range of 1:6 to 6:1.

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