Aircraft with composite structural components and method for forming composite structural components - Patents.com

Abstract

To provide a method for fabricating a composite wing structural component for an aircraft.SOLUTION: The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by an R part of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.SELECTED DRAWING: None

Description

[Technical field]

[0001] The present invention relates to aircraft, and more particularly to aircraft components of composite construction with spaces containing fill material. [Background technology]

[0002] A typical aircraft includes a mechanical structure formed of skin panels bonded to an underlying airframe. The skin panels form the surfaces acted upon by aerodynamic forces during flight. Because the skin panels may be made relatively light and thin to reduce the overall weight of the aircraft and increase its potential payload and range, the airframe includes structures configured to stiffen the skin panels and to direct aerodynamic forces acting on the skin panels to load-bearing support structures. Thus, the airframe prevents undesirable flexing, vibration, and other types of movement of the skin panels while distributing the forces to locations configured to bear the loads.

[0003] In some aircraft, structures referred to as "stringers" are used to stiffen skin panels and transmit aerodynamic forces acting on the skin panels to load-bearing structures, such as spars and / or ribs. Stringers can take a variety of forms and material compositions. In some examples, stringers are formed from composite materials (e.g., carbon fiber-epoxy composites). Depending on the cross-sectional shape of such stringers, stringers may be formed from two or more different parts that are fused or otherwise joined together. One example of such a composite stringer has a blade-shaped cross-section with flanges and a web, formed by fusing together two curved stringer sections, each stringer section including a web section, a flange section, and a radius between the web section and the flange section. The radius forms a space at the flange section of the stringer where the two stringer sections meet. This space may be filled with a filler, referred to herein as a filler or radius filler, to further stiffen the composite stringer.

[0004] Because stringers may be positioned longitudinally along a portion of an aircraft body, such as along a wing, the length of the stringer, and therefore the length of filler added to the space, may be relatively long. For example, when located on the wing of a commercial aircraft, the length of a composite wing stringer may range from 80 to 100 feet. There are various challenges to manufacturing filler segments of this range of length. For example, if the filler part is formed by extruding the filler into a mold formed by a die, a die of the required length would occupy significant valuable factory space. Furthermore, as the length of the filler part increases, so does the number of personnel required to handle the filler part (e.g., remove the filler from the die and transfer it to the stringer space). Assisted lifts can be used to extract the manufactured filler parts, but such tools can cause production flow issues and consume valuable space on clean room storage and manufacturing floors. Thus, in view of the above, challenges exist to manufacture filler segments for composite stringers and potentially other composite structural components. Summary of the Invention

[0005] Described herein is a method of manufacturing a composite structural component for an aircraft. In this aspect, the method includes extruding a filler into each of a plurality of mold channels of a die to form a plurality of filler segments, and removing the plurality of filler segments from the plurality of mold channels of the die. The method further includes disposing the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component such that the filler segments are in end-to-end contact. The method further includes curing the plurality of filler segments in the space to fuse the plurality of filler segments together.

[0006] As further described herein, an aircraft includes a fuselage and a wing extending from the fuselage. In this aspect, the wing includes a composite wing stringer including a flange, a web, and a radius where the flange and web meet, the radius defining a space. The composite wing stringer further includes a radius filler positioned within the space, the radius filler including a plurality of filler segments each blended with one or more adjacent filler segments arranged end-to-end.

[0007] Further described herein is a composite wing stringer for an aircraft, the composite wing stringer including a flange, a web extending from the flange, and a radius where the flange and the web meet, the radius defining a space. The composite wing stringer further includes a radius filler positioned within the space, the radius filler including a plurality of filler segments each fused end-to-end with one or more adjacent filler segments.

[0008] Further described herein is a die for forming a radius filler for a composite aircraft wing stringer, the die including a plurality of mold channels disposed across a surface of the die; each mold channel is shaped to form a radius filler segment for the radius filler.

[0009] The features, functions, and advantages that have been discussed may be realized individually in various embodiments or may be combined in yet further embodiments, which may be understood in further detail with reference to the following description and drawings. [Brief description of the drawings]

[0010] [Figure 1] FIG. 1 shows a diagram illustrating an aircraft according to one embodiment of the present disclosure. [Figure 2A] FIG. 2 shows a diagram illustrating a cross section of a composite wing stringer according to one embodiment of the present disclosure. [Figure 2B] FIG. 2 shows a diagram illustrating a cross section of a composite wing stringer according to one embodiment of the present disclosure. [Diagram 3]FIG. 2C shows an illustrative diagram of an apparatus including a rotary die for manufacturing the example composite wing stringer radius filler segments of FIGS. 2A-B. [Figure 4A] 4A-4D show views of the rotary die of FIG. 3 in various states for producing an exemplary radius filler segment. [Figure 4B] 4A-4D show views of the rotary die of FIG. 3 in various states for producing an exemplary radius filler segment. [Figure 4C] 4A-4D show views of the rotary die of FIG. 3 in various states for producing an exemplary radius filler segment. [Diagram 5] 2A-B in accordance with one embodiment of the present disclosure. [Figure 6A] FIG. 4 shows a schematic illustration of two radius filler segments positioned in end-to-end contact in a space defined by the radius of the composite wing stringer of FIGS. 2A-B before curing. [Figure 6B] FIG. 6B shows a schematic diagram of the R-section filler after hardening of the R-section filler segment of FIG. 6A. [Figure 7] 1 shows a diagram of the operations of a method performed by one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] In view of the above considerations, a method and apparatus is provided for manufacturing radius fillers in segments that are fused after placement. Briefly, filler is extruded into multiple die channels of a die, thereby forming multiple filler segments. The filler segments are removed from the die and placed in end-to-end contact in the space where the web and flange of a composite wing stringer meet, or in the space of another structural component. The filler segments are then cured to fuse the segments together, thereby forming a single filler structure. Manufacturing radius fillers from multiple filler segments allows for the use of compact dies, thus saving space occupied by dies and other manufacturing tools, reducing labor, and reducing the complexity of the filler manufacturing process.

[0012] FIGURE 1 illustrates an exemplary aircraft 100 having a mechanical structure formed in part by a skin 102 that is bonded to an underlying fuselage 104. Among other components, the fuselage 104 includes a fuselage 106 and a wing 108 extending from the fuselage 106. FIGURE 1 illustrates a portion of the skin 102 removed from the wing 108 and shows various structural components of the wing 108, including a wing stringer 110 that extends from the wing root to the wing tip. The wing stringer 110 is bonded to a number of ribs (e.g., rib 112) and to the skin 102 of the wing 108. The wing stringer 110 thus stiffens and strengthens the skin 102 of the wing 108, and also transmits aerodynamic forces acting on the wing skin to a number of ribs and other load-bearing components of the fuselage 104.

[0013] The wing stringer 110 may be formed from a composite material (e.g., a carbon fiber-epoxy composite). A composite structural component, as used herein, refers to a structural component that is made of composite sections and assembled to make a structural component, such as, for example, a beam, a spar, a stringer, or any similar load-bearing support structure. In such an example, the wing stringer 110 is a composite structural component referred to as a "composite wing stringer." The composite wing stringer 110 may be manufactured by joining multiple parts together. As noted above, some wing stringer sections include a radius that, when joined together, forms a space not occupied by stringer material. This space may thus be filled with segments of radius filler material that are manufactured and placed in the wing stringer and fused as described herein.

[0014] 2A-B show cross-sectional views of a wing stringer 110 adhered to a skin panel 200 forming part of the skin 102 (FIG. 1). In the illustrated example, the wing stringer 110 includes a composite blade stringer formed by a first stringer portion 202A joined with a second stringer portion 202B. The composite wing stringer 110 includes a flange 204 and a web 206 formed by joining the first stringer portion 202A and the second stringer portion 202B. As shown in FIG. 2A, both stringer portions 202 include a radius (shown at 208 for the second stringer portion 202B) where the flange and web meet, which together define a space 210. The space 210 may be along the length of the stringer 110. As will be described in further detail below, after joining of stringer sections 202A and 202B, space 210 is filled with a plurality of radius filler segments 211 that extend along the length of the stringer to form a single radius filler 212, as shown in FIG. 2B. The stringer assembly is then cured to fuse the various components together to form stringer 110. Curing of the assembly fuses the radius filler segments to form a radius filler in space 210, as indicated by the cross-hatching of space 210. In this process, the radius filler segments also fuse to stringer sections 202A and 202B. The radius filler may thereby strengthen the structural integrity of composite wing stringer 110 and its ability to transmit forces acting on the skin panel 200 to the load-bearing structure of airframe 104. The approaches described herein for forming radius fillers for wing stringers may be applicable to other types of stringers, non-stringer structural components (e.g., longerons), and wing stringer shaped parts other than those shown in Figures 2A-B.

[0015] FIG. 3 illustrates an apparatus 300 including a rotary die 302 for manufacturing radius filler segments for a composite wing stringer 110 (FIG. 1). The rotary die 302 includes a plurality of mold channels 304, including mold channel 304A, arranged around the periphery of a rotary die face 306 (best shown in FIG. 4A). Each mold channel is shaped to form a radius filler segment that may be arranged end-to-end with other radius filler segments and then fused to form a radius filler for the composite wing stringer 110. As such, each mold channel has a cross-section (FIGS. 2A-B) that matches the shape of a space 210 such that a radius filler segment 211 formed in the mold channel 304 fills the space 210 when inserted therein.

[0016] An exemplary radius filler segment manufacturing process includes extruding filler material 307 from extrusion orifice 308 into die channel 304B. For example, by moving one or both of rotary die 302 and orifice 308 as shown by arrow 309, filler material 307 is deposited into the length of die channel 304B. In some cases, a compression machine such as compression wheel 310 compresses filler material 307 so that filler material 307 assumes the shape of the die channel. Although a compression wheel is shown diagrammatically in FIG. 3, any other suitable structure may be used to compress filler material 307 and firmly press the extruded filler material 307 into the die channel. When extruded into die channel 304, filler material 307 forms radius filler segment 211 configured to fill space 210 of composite wing stringer 110 (FIGS. 2A-B), thereby reinforcing wing stringer 110. The filler material 307 may comprise any suitable material including, but not limited to, a discontinuous carbon (e.g., graphite) fiber material comprising fiber segments and an epoxy (thermoset) matrix that may be fused to other stringer components during a curing process.

[0017] Each die channel 304 is angularly offset from adjacent die channels around the periphery 305 of the rotary die 302 such that extruding the filler material 307 into the die channels involves rotating the rotary die 302 during each extrusion. FIGS. 4A-C illustrate partial views of the rotary die 302 in individual rotational orientations during the extrusion process. In FIG. 4A, the first die channel 304A is filled with filler material 307, thereby forming a first radius filler segment 402A. In FIG. 4B, the rotary die 302 is rotated and the second die channel 304B is filled with filler material 307, thereby forming a second radius filler segment 402B. In FIG. 4C, the rotary die 302 is rotated through eight extrusions, and eight radius filler segments are formed in the die channels. As described below, the radius filler segments 402 may be removed (e.g., in some embodiments after a cooling period) from the mold channels disposed in end-to-end contact with the space 210 defined by the radius of the composite wing stringer 110 and fused together to form a single radius filler 212 that fills the space 210 of the composite wing stringer 110. Additionally, in some examples, an interface material, such as a tape comprising polytetrafluoroethylene (e.g., Teflon tape available from The Chemours Company of Wilmington, Del.), may be placed in each mold channel 304, and the filler material 307 is deposited in each mold channel 304 over the interface material. The interface material may aid in releasing the radius filler segments 402 formed by the filler material 307 from the mold channels 304. Alternatively or additionally, the rotary die 302 may be coated with a release agent (e.g., FREKOTE, available from Henkel AG & Company, Düsseldorf, Germany) to facilitate removal of the radius filler segments 402. Additionally, the rotary die 302 may include a tooling foam and / or any other suitable material.

[0018] In the example of FIGS. 3-4C, where each die channel has a length of 10 feet, eight 10 foot radius filler segments may be formed and later formed together to form an 80 foot radius filler for an 80 foot long void, for example, in a composite wing stringer. In other embodiments, the rotary die 302 may be configured with any other suitable length and / or number of die channels. As a further example, the rotary die 302 may be rotated between 6 and 10 extrusions, with the filler extruded into die channels each having a length between 8 and 12 feet. In other embodiments, the rotary die may have any other suitable configuration based on the shape of the void to be filled using the rotary die. Additionally, although the example of FIGS. 4A-C shows the portions immediately adjacent each die channel as being substantially flat such that the rotary die 302 includes a polygonal perimeter 404 having a number of flat surfaces 406, each flat surface may host a die channel, and in other embodiments, the portions immediately adjacent each die channel may have a curved shape in the circumferential direction, or may exhibit any other suitable shape in the circumferential direction. Also, in some embodiments, multiple dies may be arranged (e.g., in parallel and / or in series) for filling through the same extrusion orifice, where each die of the multiple dies includes multiple die channels, and each die is coupled to a motor to enable rotation of the die. An extrusion system may then be used to sequentially extrude filler material into each die channel of each die of the multiple dies. This may help to increase the throughput of the radius filler material manufacturing system. Furthermore, in some embodiments, the rotating die 302 may be removable from the apparatus 300 (e.g., from the rotating mandrel of the apparatus), allowing different dies to be switched in and out of the apparatus. This may help to increase the manufacturing throughput. When dies with different die channel geometries are used, such dies may be switched to produce filler material segments with potentially different profiles at high throughput.

[0019] As shown in the embodiment illustrated in FIG. 3, the apparatus 300 can rotate the rotary die (e.g., via a thrust bearing) using a motor 312 during each extrusion. Additionally, the apparatus 300 can control the extrusion into the die channel 304, as an example, using a light sensing system 313 configured to image the die channel (e.g., via one or more lasers, cameras, or other similar imaging devices) and a feedback mechanism configured to provide a signal to the motor 312 that prompts the rotation of the rotary die 302. Additionally, in some embodiments, parallel grippers 314 can be used to hold and / or guide the radius filler 307 as it is extruded to aid in the placement of the material. In other embodiments, any other suitable mechanism can be used to control the extrusion into the rotary die 302. For example, the parallel grippers 314 can be omitted and the compression wheel 310 can be used without parallel grippers to place the radius filler in the die channel 304.

[0020] The techniques described herein for producing radius filler segments can be applied to dies other than rotary dies having circumferentially arranged die channels. As another example, FIG. 5 shows a planar die 500 that can be used to form radius filler segments for composite wing stringers. Planar die 500 includes multiple die channels (e.g., die channel 502) that are each laterally offset from one or more adjacent die channels on a substantially flat surface 504 of the planar die, where extruding filler into each die channel includes changing the relative lateral position of planar die 500 and extrusion orifice during each extrusion. In any embodiment, each die channel may have the same length, while in other embodiments, one or more die channels may have different lengths.

[0021] As described above, the radius filler segments manufactured according to the described techniques may be placed in the space 210 (FIGS. 2A-B) and cured, thereby fusing the filler segments with each other and with other stringer portions. FIGS. 6A and 6B respectively illustrate schematic illustrations of the placement of the radius filler in the space 21 defined by the composite wing stringer 110 before and after the radius filler is cured. In FIG. 6A, two radius filler segments 600A and 600B are placed in end-to-end contact (e.g., adjacent and directly contacting) in the space 210. In FIG. 6B, the radius filler segments are cured to form a single radius filler 602. The curing process also bonds the radius filler segment 602 with other portions of the composite wing stringer 110 (e.g., portions 202A and 202B of FIG. 2A-B) to form a single structure 604 comprising the composite wing stringer 110 and the radius filler 602. In this manner, a plurality of composite wing stringers may be formed that include corresponding radius fillers having a plurality of filler segments fused with one or more adjacent filler segments in an end-to-end arrangement.

[0022] In some examples, curvature filler segments 600A and 600B include heating curvature filler segment 600 to form curvature filler 602. For example, curvature filler segments 600A and 600B may be heated to approximately 350° C. to initiate and carry out a curing process to chemically fuse and crosslink the polymeric resin material or other suitable material that forms composite wing stringer 210 and curvature filler segments 600A and 600B. In other examples, any other suitable curing process may be used, such as a light initiated curing process.

[0023] 7 shows a flow diagram illustrating a method 700 for manufacturing a composite structural component for an aircraft. The method 700 may be implemented to manufacture a composite wing stringer 110, as an example.

[0024] At 702, method 700 includes extruding a filler material (e.g., filler material 307) into each die channel of a plurality of die channels (e.g., die channel 304) of a die (e.g., rotary die 302) to form a plurality of filler segments (e.g., filler segment 600). In some embodiments, extruding the filler material may include rotating 704 the rotary die during each extrusion. In other embodiments, extruding the filler material may include varying 706 a relative lateral position of a planar die (e.g., planar die 500) and an extrusion orifice (e.g., extrusion orifice 308) during each extrusion. Additionally, in some embodiments, method 700 may include arranging a plurality of dies, as shown at 707, where each die of the plurality of dies includes a plurality of die channels, and sequentially extruding the filler material into each die channel of each die of the plurality of dies.

[0025] At 708, the method 700 may include compressing the filler material while extruding the filler material into each of the plurality of die channels (e.g., by a compression wheel following an extrusion orifice). At 710, the method 700 may include removing the plurality of filler material segments from the plurality of die channels of the die. The plurality of filler material segments may be removed from the plurality of die channels after a cooling period 712. In some embodiments, the plurality of die channels may be covered with an interface material (e.g., Teflon tape) or coating (e.g., FREKOTE) to facilitate removal of the plurality of filler material segments.

[0026] At 714, the method 700 further includes disposing a plurality of filler segments in a space in the composite stringer, the space being defined by a radius of the composite stringer such that the filler segments contact end-to-end in the composite structural component. The plurality of filler segments may be disposed in the space 716 where the web and flange of the composite stringer meet in some embodiments, or in any other suitable space in other embodiments.

[0027] At 718, the method 700 includes curing the plurality of filler segments in the space to fuse the plurality of filler segments. Curing the plurality of filler segments may include heating the plurality of filler segments 720. Curing the plurality of filler segments forms a unitary structure 722 having a composite structure.

[0028] The apparatus and processes described herein have the potential benefit of reducing complexity, labor, and physical space consumption in the manufacture of radius fillers for composite wing stringers and other structures. For example, forming multiple filler segments and curing the multiple filler segments to form the radius filler may allow for the use of smaller dies to form multiple filler segments. As another example, the use of a rotary die may allow the apparatus to at least partially automate the extrusion of the filler material, with the filler segments being formed by rotating the rotary die during extrusion. As another example, extruding the filler material into a die channel of a die having a length between 8 and 12 feet may allow for a reduction in labor spent handling the filler segments. As another example, the use of a planar die may allow the apparatus to at least partially automate the extrusion of the filler material, with the filler segments being formed by changing the relative position of the extrusion orifice and the planar die. As another example, pressurizing the filler material while extruding it into a die channel of a die may allow for the formation of a filler segment having a desired shape that fills a space defined by a radius of a composite structural component. As another example, removing the filler segments from the mold channels after a cooling period may facilitate the desired formation of the filler segments having desired material properties. As another example, curing the filler segments by heating them may facilitate fusing the filler segments with each other and to the composite structural component to form a single structure. As another example, arranging multiple dies and sequentially extruding the filler into the mold channels of each of the multiple dies may allow for an increase in the number of filler segments formed and therefore a reduction in manufacturing time for manufacturing a filled composite structural component. As another example, placing filler segments in the spaces where the webs and flanges of a composite structural component meet may allow for the manufacture of a relatively strong composite structural component that reinforces the first component and transmits forces acting on the first component to the second component.As another example, filling composite structural components with radius fillers formed by fusing filler segments together may enable the production of stronger airframes with greater load-bearing capabilities.

[0029] Furthermore, the present disclosure includes embodiments according to the following clauses:

[0030] Clause 1. A method (700) for manufacturing a composite structural component (110) for an aircraft (100), comprising: extruding (702) a filler material (307) into each die channel (304) of a plurality of die channels (304) of a die (302) to form a plurality of filler material segments (600); removing (710) the plurality of filler segments (600) from the plurality of mold channels (304) of the die (302); placing (714) the plurality of filler segments (600) in a space (210) of the composite structural component (110) defined by a radius (208) of the composite structural component (110) such that the filler segments (600) are in end-to-end contact; and curing (718) the plurality of filler segments (600) in the space (210) to fuse the plurality of filler segments (600); Including, method.

[0031] Clause 2. The method (700) of clause 1, wherein each die channel (304) is angularly offset from adjacent die channels (304) around a polygonal periphery (404) of the die (302), and extruding (702) the filler material (307) into each die channel (304) of the plurality of die channels (304) of the die (302) includes rotating (704) the die (302) during each extrusion.

[0032] Clause 3. The method (700) of clause 2, wherein rotating (704) the die (302) during each extrusion comprises rotating (704) the die (302) during between 6 and 10 respective extrusions.

[0033] Clause 4. The method (700) of any one of clauses 1 to 3, wherein extruding (702) the filler material (307) into each die channel (304) includes extruding (702) the filler material (307) into the die channel (304) having a length between 8 and 12 feet.

[0034] Clause 5. The method (700) of any one of clauses 1 to 4, wherein each die channel (304) is laterally offset from one or more adjacent die channels (304) on a substantially flat surface (504) of the die (500), and extruding (702) the filler material (307) into each die channel (304) includes varying (706) the relative lateral position of the die (500) and extrusion orifice (308) during each extrusion.

[0035] Clause 6. The method (700) of any one of clauses 1 to 5, further comprising pressurizing (708) the filler material (307) while forcing the filler material (307) into each of the plurality of mold channels (304).

[0036] Clause 7. The method (700) of any one of clauses 1 to 6, further comprising removing (710) the plurality of filler segments (600) from the plurality of mold channels (304) after a cooling period.

[0037] Clause 8. The method (700) of any one of clauses 1 to 7, wherein curing (718) the plurality of filler segments (600) comprises heating (720) the plurality of filler segments (600).

[0038] Clause 9. The method (700) of any one of clauses 1 to 8, wherein curing (718) the plurality of filler segments (600) bonds the plurality of filler segments (600) to other portions (202) of the composite structural component (110) to form a unitary structure (604).

[0039] Clause 10. The method (700) of any one of clauses 1 to 9, further comprising: disposing (707) a plurality of dies (302), each die (302) of the plurality of dies (302) including a plurality of die channels (304); and sequentially extruding (702) the filler material (307) into each die channel (304) of each die (302) of the plurality of dies (302).

[0040] Clause 11. The method (700) of any one of clauses 1 to 10, wherein disposing (714) the plurality of filler segments (600) in the space (210) comprises disposing (714) the plurality of filler segments (600) in the space (210) where a web (206) and a flange (204) of the composite structural component (110) meet.

[0041] Clause 12. An aircraft (100), torso (106); and a wing (108) extending from the fuselage (106), Flange (204), Web (206), a radius (208) where the flange (204) and the web (206) meet, the radius (208) defining a space (210) therebetween; and a radius filler (602) positioned within the space (210), the radius filler (602) including a plurality of filler segments (600) each fused with one or more adjacent filler segments (600) arranged end-to-end; a wing (108) including a composite wing stringer (110); Equipped with Aircraft (100).

[0042] Clause 13. The aircraft (100) of clause 12, wherein the filler segment (600) is fused to the web (206) and the flange (204) to form a unitary structure (604).

[0043] Clause 14. The aircraft (100) of clause 12 or 13, wherein the composite wing stringer (110) comprises a blade stringer (110).

[0044] Clause 15. The aircraft (100) of any one of clauses 12 to 14, wherein each of the plurality of wing stringers (110) further comprises a corresponding radius filler (602).

[0045] Clause 16. The aircraft (100) of any one of clauses 12 to 15, wherein each filler segment (600) comprises a length between 8 feet and 12 feet.

[0046] Clause 17. A composite wing stringer (110) for an aircraft (100), comprising: Flanges(204); a web (206) extending from said flange (204); a radius (208) where the flange (204) and the web (206) meet, the radius (208) defining a space (210); and a radius filler (602) positioned within the space (210), the radius filler (602) including a plurality of filler segments (600) each fused end-to-end with one or more adjacent filler segments (600); Including, Composite wing stringer(110).

[0047] Clause 18. The composite wing stringer (110) of clause 17, wherein the plurality of filler segments (600) form a unitary structure (604).

[0048] Clause 19. The composite wing stringer (110) of clause 17 or 18, wherein the composite wing stringer (110) comprises a blade stringer (110).

[0049] Clause 20. The composite wing stringer (110) of any one of clauses 17 to 19, wherein each filler segment (600) comprises a length of between 8 feet and 12 feet.

[0050] Clause 21. A die (302) for forming a radius filler (602) for a composite aircraft wing stringer (110), the die (302) including a plurality of mold channels (304) disposed across a surface (306) of the die (302), each mold channel (304) being shaped to form a radius filler segment (600) for the radius filler (602).

[0051] Clause 22. The die (302) of clause 21, wherein the mold channels (304) are angularly offset around a polygonal periphery (404) of the die (302).

[0052] Clause 23. The die (302) of clause 21 or 22, wherein the mold channels (304) are laterally offset across a substantially flat surface (504) of the die (500).

[0053] The present disclosure includes all novel and non-obvious combinations and subcombinations of the various features and techniques disclosed herein. The various features and techniques disclosed herein are not necessarily required for all embodiments of the present disclosure. Moreover, the various features and techniques disclosed herein may define patentable subject matter apart from the disclosed embodiments and may find utility in other implementations not expressly disclosed herein.

Claims

1. A method (700) for manufacturing a composite structural component (110) for an aircraft (100), comprising: extruding (702) a filler material (307) into each die channel (304) of a plurality of die channels (304) of a die (302) to form a plurality of filler material segments (600); removing (710) the plurality of filler segments (600) from the plurality of mold channels (304) of the die (302); placing (714) the plurality of filler segments (600) in a space (210) of the composite structural component (110) defined by a radius (208) of the composite structural component (110) such that the filler segments (600) are in end-to-end contact; and curing (718) the plurality of filler segments (600) in the space (210) to fuse the plurality of filler segments (600); Including, Method (700).

2. 2. The method (700) of claim 1, wherein each die channel (304) is angularly offset from adjacent die channels (304) around a polygonal perimeter (404) of the die (302), and extruding (702) the filler material (307) into each die channel (304) of the plurality of die channels (304) of the die (302) includes rotating (704) the die (302) during each extrusion.

3. 3. The method (700) of claim 2, wherein rotating (704) the die (302) during each extrusion comprises rotating (704) the die (302) during between 6 and 10 respective extrusions.

4. 4. The method (700) of any one of claims 1 to 3, wherein extruding (702) the filler material (307) into each die channel (304) comprises extruding (702) the filler material (307) into the die channel (304) having a length between 8 and 12 feet.

5. 10. The method (700) of claim 1, wherein each die channel (304) is laterally offset from one or more adjacent die channels (304) on a substantially flat surface (504) of the die (500), and extruding (702) the filler material (307) into each die channel (304) includes varying (706) a relative lateral position of the die (500) and extrusion orifice (308) during each extrusion.

6. 6. The method (700) of any one of claims 1 to 5, further comprising pressurizing (708) the filler material (307) while extruding the filler material (307) into each of the plurality of die channels (304).

7. The method (700) of any one of claims 1 to 6, further comprising removing (710) the plurality of filler segments (600) from the plurality of mold channels (304) after a cooling period.

8. The method (700) of any one of claims 1 to 7, wherein curing (718) the plurality of filler material segments (600) comprises heating (720) the plurality of filler material segments (600).

9. 9. The method (700) of any one of claims 1 to 8, wherein curing (718) the plurality of filler segments (600) bonds the plurality of filler segments (600) to other portions (202) of the composite structural component (110) to form a unitary structure (604).

10. 10. The method (700) of any one of claims 1 to 9, further comprising: disposing (707) a plurality of dies (302), each die (302) of the plurality of dies (302) including a plurality of die channels (304); and sequentially extruding (702) the filler material (307) into each die channel (304) of each die (302) of the plurality of dies (302).

11. 11. The method (700) of any one of claims 1 to 10, wherein placing (714) the plurality of filler segments (600) in the space (210) comprises placing (714) the plurality of filler segments (600) in the space (210) where a web (206) and a flange (204) of the composite structural component (110) meet.

Images