Radius Filler Formation System for Composite Structures
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Solution Overview
Problem
Traditional methods for forming radius fillers for composite structures lack precise control over shape and are labor-intensive, often resulting in voids between composite material sheets during the curing process.
Innovation Solution
A system comprising a sheet-locating structure, a separation device, and a conveyance structure that selectively extends and separates composite material sheets to form strips, which are then conveyed onto a layup surface to create a stack defining the radius filler, allowing for precise control over the shape and cross-sectional profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional radius fillers utilize a single length of composite material that is creased to form an accordion shape and then molded, then the manufacturing process is simpler, but the shape control of the radius filler is not tight and labor intensity is high
Solution Approach 1:
The invention divides the composite material into multiple individual strips rather than using a single creased length. Each strip is separated and positioned independently, allowing for precise control of the radius filler shape while maintaining manufacturing efficiency through automated handling of the segmented strips.
2Manufacturing precision
If traditional radius fillers manually stack multiple lengths of composite material to form parallel planes, then the shape can be controlled, but the process becomes labor-intensive
Solution Approach 1:
The system uses automated conveyance structures and positioning mechanisms that self-position the composite strips without manual intervention. The strips are automatically fed, separated, and stacked in the correct configuration, eliminating labor-intensive manual stacking while maintaining precise shape control.
3Strength
If the finite thickness and mechanical stiffness of composite sheets are maintained, then the structural integrity is preserved, but a finite bend radius is created that results in void spaces between adjacent sheets
Solution Approach 1:
The radius filler is pre-formed with the exact shape needed to fill the void space that will be created by the bend in the composite sheets. By anticipating the void formation due to sheet thickness and stiffness, the filler is prepared in advance with complementary geometry to perfectly fit and eliminate the void before the composite structure is finalized.
Data Source
AI summary
Systems and methods for forming radius fillers for composite structures are disclosed herein. The systems include a sheet-locating structure that has a support surface and a support surface edge. The systems further include a separation device, a conveyance structure, and a layup surface. The methods include locating a sheet of composite material on a first support surface and translating the sheet of composite material such that a first portion of the sheet is supported by the first support surface and a second portion of the sheet extends past the support surface edge. The methods also include separating the second portion of the sheet from the first portion of the sheet to form a strip of composite material. The methods further include conveying the strip of composite material onto a layup surface and repeating the methods to form the radius filler from a plurality of strips of composite material.