# US 11,897,191 B2 · Lattice reinforced radius filler

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- Number: US 11,897,191 B2
- Document ID: US11897191B2
- Status: Granted
- Kind: B2
- Application number: 16/916,035
- Filed: 2020-06-29
- Published: 2021-03-18
- Granted: 2024-02-13
- Earliest claimed: 2014-06-13
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: Charles William Thomas; Benjamin Jeffrey Stephenson
- Web page: https://patentgrep.com/patent/US11897191B2

## CPC

- B29C 64/153: using layers of powder being selectively joined, e.g. by selective laser sintering or melting
- B22F 10/28: Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
- B22F 10/60: Treatment of workpieces or articles after build-up
- B29C 39/028: {having an axis of symmetry}
- B29C 39/10: incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(coating a surface by casting in general B05D1/30, B29C39/126 takes precedence)}
- B29D 99/0005: {Producing noodles, i.e. composite gap fillers, characterised by their construction}
- B29D 99/0014: {provided with ridges or ribs, e.g. joined ribs}
- B33Y 80/00: Products made by additive manufacturing
- B64C 1/064: {Stringers; Longerons}
- B64C 1/12: Construction or attachment of skin panels
- B64C 3/182: {Stringers, longerons}
- B64C 3/20: Integral or sandwich constructions
- B64C 3/26: Construction, shape, or attachment of separate skins, e.g. panels
- B22F 10/00: Additive manufacturing of workpieces or articles from metallic powder (apparatus or devices therefor B22F12/00)
- B29C 70/48: and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM] {, e.g. by vacuum}
- B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material
- B29K 2705/08: Transition metals
- B29K 2995/0077: Yield strength; Tensile strength
- B29K 2995/0096: Dimensional stability
- B29L 2009/003: {comprising a metal layer}
- B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)}
- B64C 2001/0072: {from composite materials}
- Y02P 10/25: Process efficiency
- Y02T 50/40: Weight reduction
- Y10T 428/249921: Web or sheet containing structurally defined element or component
- 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)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B64C: AEROPLANES; HELICOPTERS
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A method and apparatus for forming a radius filler. A lattice is formed of connecting elongate members having a three-dimensional shape of the radius filler. A resin is placed within the lattice.

## Claims

### Claim 1

An apparatus that comprises:
a lattice shaped as a one-piece additive manufactured structure that comprises unified elongate members that form a first curved peripheral side, a second curved peripheral side, and a third peripheral side, wherein:
a first elongate member of the unified elongate members extends from the first curved peripheral side to the second curved peripheral side: and
a second elongate member of the unified elongate members extends from the first curved peripheral side to the third peripheral side; and
a resin that fills all space between the unified elongate members in the lattice and forms a radius filler.

### Claim 2 (depends on 1)

The apparatus of claim 1, wherein the unified elongate members comprise a sintered powder.

### Claim 3 (depends on 1)

The apparatus of claim 1, wherein the resin is in a state selected from one of: a cured state, a partially cured state, and an uncured state, within the lattice and forms a radius filler.

### Claim 4 (depends on 1)

The apparatus of claim 1, wherein the lattice is selected from one of a regular lattice, an irregular lattice, a grid, a space frame, a Bravis lattice, and interconnected spring shapes.

### Claim 5 (depends on 1)

The apparatus of claim 1, wherein the lattice is comprised of a material selected from at least one of: a metal, a metal alloy, titanium, Invar, aluminum, steel, plastic, ceramic, a cured composite material, or carbon fibers.

### Claim 6 (depends on 1)

The apparatus of claim 1, wherein the resin is selected from one of: a thermoplastic polymer, a thermoset polymer, and a metal.

### Claim 7 (depends on 3)

The apparatus of claim 3, wherein a geometry of the unified elongate members in the lattice distributes loads in directions of an x-axis, a y-axis, and a z-axis for the radius filler in which the z-axis extends centrally through the radius filler.

### Claim 8

A radius filler that comprises:
a lattice shaped as a one-piece additive manufactured structure that comprises a sintered metal powder configured to form unified elongate members that comprise: a first curved peripheral side, a second curved peripheral side, and a third peripheral side, configured to fill a channel in a composite part, wherein:
a first elongate member of the unified elongate members extends from the first curved peripheral side to the second curved peripheral side; and
a second elongate member of the unified elongate members extends from the first curved peripheral side to the third peripheral side; and
a resin that fills any space between the unified elongate members, wherein the lattice and the resin comprise a number of desired performance parameters that comprise a stiffness.

### Claim 9 (depends on 8)

The radius filler of claim 8, wherein the sintered metal powder is selected from one of titanium, steel, aluminum, Invar, and a metal alloy.

### Claim 10 (depends on 8)

The radius filler of claim 8, wherein the number of desired performance parameters further comprise at least one of: a load, a coefficient of thermal expansion, a toughness, a fracture resistance, or a strength.

### Claim 11

A lattice shaped as a single additive manufactured structure configured to fill a void formed between walls of connected parts, such that the lattice comprises:
unified elongate members that form a first curved peripheral side, a second curved peripheral side, and a third peripheral side, of the lattice, wherein:
a first elongate member of the unified elongate members extends from the first curved peripheral side to the second curved peripheral side; and
a second elongate member of the unified elongate members extends from the first curved peripheral side to the third peripheral side;
the lattice conforms to a shape of the void and is configured to touch every wall of the void such that loads applied to the lattice distribute along an x-axis, a y-axis, and a z-axis; and
an interior infused with a resin that fills any space between the unified elongate members.

### Claim 12 (depends on 11)

The lattice of claim 11, wherein the elongate members comprise a sintered powder and a design configured to inhibit propagation of an inconsistency in a connection between the connected parts.

### Claim 13 (depends on 11)

The lattice of claim 11, wherein the unified elongate members are cured to each other.

### Claim 14 (depends on 11)

The lattice of claim 11, wherein a wall of the walls comprises a curved shape.

### Claim 15 (depends on 11)

The lattice of claim 11, wherein the unified elongate members comprise a metal.

### Claim 16 (depends on 11)

The lattice of claim 11, wherein the unified elongate members comprise titanium.

### Claim 17 (depends on 11)

The lattice of claim 11, wherein the void and the lattice each extend along the z-axis, such that the void forms a channel.

### Claim 18 (depends on 11)

The lattice of claim 11, wherein the unified elongate members comprise sintered powder.

### Claim 19 (depends on 11)

The lattice of claim 11, wherein the shape of the lattice conforms to a design from a computer-aided model of the connected parts.

### Claim 20 (depends on 19)

The lattice of claim 19, wherein the design comprises performance parameters, for a radius filler that comprises the lattice and the resin, selected from at least one of: a load, a coefficient of thermal expansion, a toughness, a fracture resistance, a stiffness, or a strength.