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US 9,802,385 B2Granted
Method constructing a fabric jacketed unidirectional noodle
AssigneeThe Boeing Company
InventorsJoshua Zarfos, Vladislav A. Andryukov, Darrell D. Campbell, Jr.
Life of this patent
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Abstract
A method of constructing a composite, radius filler noodle for a co-cured spar or stringer used in aircraft construction includes forming a core of the noodle from unidirectional pre-preg tape and stacking pluralities of pre-prep fabric strips in layers surrounding the core.
Claims20
A method of constructing a composite, radius filler noodle, the method comprising:
- constructing a core of unidirectional pre-preg tape that is formed into a triangular cross-section configuration with first, second and third surfaces that extend along a length of the core;
- stacking a plurality of pre-preg fabric first strips on the first surface of the core with lengths of the plurality of pre-preg fabric first strips extending completely along the length of the core and with width dimensions of the plurality of pre-preg fabric first strips extending completely across the first surface of the core, with the width dimensions of the plurality of pre-preg fabric first strips increasing as the plurality of pre-preg fabric first strips are stacked on the first surface of the core to an outermost pre-preg fabric first strip at an exterior of the composite, radius filler noodle;
- stacking a plurality of pre-preg fabric second strips on the second surface of the core with lengths of the plurality of pre-preg fabric second strips extending completely along the length of the core and with width dimensions of the plurality of pre-preg fabric second strips extending completely across the second surface of the core, with the width dimensions of the plurality of pre-preg fabric second strips increasing as the plurality of pre-preg fabric second strips are stacked on the second surface of the core to an outermost pre-preg fabric second strip at an exterior of the composite, radius filler noodle;
- stacking a plurality of pre-prep fabric third strips on the third surface of the core with lengths of the plurality of pre-preg fabric third strips extending completely along the length of the core and with width dimensions of the plurality of pre-preg fabric third strips extending completely across the third surface of the core, with the width dimensions of the plurality of pre-preg fabric third strips increasing as the plurality of pre-preg fabric third strips are stacked on the third surface of the core to an outermost pre-preg fabric third strip at an exterior of the composite, radius filler noodle.
1 more element
A method of constructing a composite, radius filler noodle comprising:
- constructing a core of unidirectional pre-preg tape that is pultruded into a triangular cross-section configuration with first, second and third surfaces that extend along a length of the core;
- applying a pre-preg fabric first strip on the first surface of the core with a length of the pre-preg fabric first strip extending completely along the length of the core and a width of the pre-preg fabric first strip extending completely across a width dimension of the first surface of the core;
- applying a pre-preg fabric second strip on the second surface of the core with a length of the pre-preg fabric second strip extending completely along the length of the core and a width dimension of the pre-preg fabric second strip extending completely across a width dimension of the second surface of the core;
- applying a pre-preg fabric third strip on the third surface of the core with a length of the pre-preg fabric third strip extending completely along the length of the core and a width dimension of the pre-preg fabric third strip extending completely across a width dimension of the third surface of the core;
- and,
- forming the pre-preg fabric second strip and the pre-preg fabric third strip with a same width dimension that is smaller than the width dimension of the pre-preg fabric first strip.
3 more elements
A method of constructing a composite, radius filler noodle comprising:
- forming a core of the noodle from unidirectional pre-preg tape with the core having a triangular cross-section configuration with first, second and third surfaces that extend a length of the core;
- applying a first pre-preg fabric strip on the core first surface with a length of the first pre-preg fabric strip extending completely along the length of the core first surface and a width of the first pre-preg fabric strip extending completely across the core first surface;
- applying a second pre-preg fabric strip on the core second surface with a length of the second pre-preg fabric strip extending completely along the length of the core second surface and a width of the second pre-preg-fabric strip extending completely across the core second surface;
- applying a third pre-preg fabric strip on the core third surface with a length of the third pre-preg fabric strip extending completely along the length of the core third surface and a width of the third pre-preg fabric strip extending completely across the core third surface;
- applying a fourth pre-preg fabric strip on the first pre-preg fabric strip with a length of the fourth pre-preg fabric strip extending completely along the length of the first pre-preg fabric strip and a width of the fourth pre-preg fabric strip being larger than the width of the first pre-preg fabric strip;
- applying a fifth pre-preg fabric strip on the second pre-preg fabric strip with a length of the fifth pre-preg fabric strip extending completely along the length of the second pre-preg fabric strip and a width of the fifth pre-preg fabric strip being larger than the width of the second pre-preg fabric strip;
- applying a sixth pre-preg fabric strip on the third pre-preg fabric strip with a length of the sixth pre-preg fabric strip extending completely along the length of the third pre-preg fabric strip and a width of the sixth pre-preg fabric strip being larger than the width of the third pre-preg fabric strip;
- applying a seventh pre-preg fabric strip on the fourth pre-preg fabric strip with a length of the seventh pre-preg fabric strip extending completely along the length of the fourth pre-preg fabric strip and a width of the seventh pre-preg fabric strip being larger than the width of the fourth pre-preg fabric strip;
- applying an eighth pre-preg fabric strip on the fifth pre-preg fabric strip with a length of the eighth pre-preg fabric strip extending completely along the length of the fifth pre-preg fabric strip and a width of the eighth pre-preg fabric strip being larger than the width of the fifth pre-preg fabric strip;
- and,
- applying a ninth pre-preg fabric strip on the sixth pre-preg fabric strip with a length of the ninth pre-preg fabric strip extending completely along the length of the sixth pre-preg fabric strip and a width of the ninth pre-preg fabric strip being larger than the width of the sixth pre-preg fabric strip.
8 more elements
Dependencies are inferred from the claim text.