# US 11,110,671 B2 · Layup support configured to provide support for laying up composite material > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,110,671 B2 - Document ID: US11110671B2 - Status: Granted - Kind: B2 - Application number: 16/294,480 - Filed: 2019-03-06 - Published: 2020-09-10 - Granted: 2021-09-07 - Earliest claimed: 2019-03-06 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Corydon D. Hilton; Bryan R. McLaughlin - Web page: https://patentgrep.com/patent/US11110671B2 ## CPC - B29C 70/543: {Fixing the position or configuration of fibrous reinforcements before or during moulding (for non-woven fabrics D04H3/08)} - B29C 37/0075: {using release sheets} - B29C 70/342: {using isostatic pressure} - B29C 70/446: {Moulding structures having an axis of symmetry or at least one channel, e.g. tubular structures, frames} - B29D 99/0014: {provided with ridges or ribs, e.g. joined ribs} - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) ## Abstract An illustrative embodiment of the present disclosure provides a method of forming a composite structure. Composite material is placed into a cavity of a mold. A layup support is placed over the cavity. A number of composite plies is laid up over the layup support, the composite material, and the cavity. ## Claims ### Claim 1 A method of forming a composite structure comprising: placing a first composite material into a cavity of a mold; placing a layup support over the first composite material and the cavity; and laying up a second composite material comprising a number of composite plies over the layup support, the first composite material, and the cavity, wherein the layup support comprises an at least partially cured composite material, a first edge having a first integrally formed filler and a second edge having a second integrally formed filler, wherein the first integrally formed filler fills a first radius formed by the first composite material and the second composite material and the second integrally formed filler fills a second radius formed by the first composite material and the second composite material. ### Claim 2 (depends on 1) The method of claim 1 further comprising: curing the number of composite plies and the composite material while the layup support is present over the cavity. ### Claim 3 (depends on 2) The method of claim 2, wherein curing the number of composite plies and the composite material forms a stiffened composite skin with the layup support bonded to the number of composite plies. ### Claim 4 (depends on 2) The method of claim 2, wherein curing the number of composite plies and the composite material forms a stiffened composite skin, the method further comprising: removing the layup support from the stiffened composite skin after curing the composite material. ### Claim 5 (depends on 1) The method of claim 1 further comprising: placing a bladder into the cavity over the composite material, wherein the layup support is placed over the bladder. ### Claim 6 (depends on 1) The method of claim 1 further comprising: placing a release film over the layup support prior to laying up the number of composite plies over the layup support. ### Claim 7 (depends on 1) The method of claim 1, wherein the layup support is formed of cured composite material, the first integrally formed filler forms a first radius filler and the second integrally formed filler forms a second radius filler. ### Claim 8 A layup support configured to provide support for laying up composite material, the layup support comprising: a first surface having a curvature configured to continue a curvature of a mold over a cavity in the mold; and a second surface opposite the first surface, the second surface facing the cavity, wherein the layup support comprises an at least partially cured composite material, a first edge having a first integrally formed filler and a second edge having a second integrally formed filler, wherein the first integrally formed filler fills a first radius formed by a first composite material and a second composite material and the second integrally formed filler fills a second radius formed by the first composite material and the second composite material. ### Claim 9 (depends on 8) The layup support of claim 8, wherein the second edge is separated from the first edge by a width of the layup support. ### Claim 10 (depends on 8) The layup support of claim 8, wherein the layup support is formed of cured composite material, the first integrally formed filler forms a first radius filler and the second integrally formed filler forms a second radius filler. ### Claim 11 (depends on 10) The layup support of claim 10, wherein the radius filler has a first cross-section shape to connect between a composite stiffener and a composite skin and the second radius filler has a second cross-section shape to connect between the composite stiffener and the composite skin. ### Claim 12 (depends on 8) The layup support of claim 8, wherein a thickness of the layup support is formed by two to four composite plies. ### Claim 13 A composite layup system comprising: a mold having a curvature and a cavity; a first composite material on the mold; a second composite material on the first composite material; and a layup support configured to provide support for laying up the second composite material on both the first composite material and the mold, the layup support comprising an at least partially cured composite material, a first edge having a first integrally formed filler, a second edge having a second integrally formed filler, a first surface having a curvature configured to continue the curvature of the mold over the cavity and a second surface opposite the first surface, wherein the first integrally formed filler fills a first radius formed by the first composite material and the second composite material and the second integrally formed filler fills a second radius formed by the first composite material and the second composite material. ### Claim 14 (depends on 13) The composite layup system of claim 13 further comprising: a bladder configured to be placed within the cavity. ### Claim 15 (depends on 13) The composite layup system of claim 13, wherein the curvature of the mold is convex. ### Claim 16 (depends on 13) The composite layup system of claim 13, wherein the first edge and the second edge are separated by a width of the layup support, wherein the width of the layup support is the same as a width of the cavity. ### Claim 17 (depends on 13) The composite layup system of claim 13, wherein the layup support further comprises a number of filler portions associated with the first edge and the second edge. ### Claim 18 (depends on 13) The composite layup system of claim 13, wherein a length of the layup support is the same as a length of the cavity. ### Claim 19 (depends on 13) The composite layup system of claim 13, wherein the layup support is formed of cured composite material, the first integrally formed filler forms a first radius filler and the second integrally formed filler forms a second radius filler. ### Claim 20 (depends on 13) The composite layup system of claim 13, wherein the curvature of the mold is planar.