Folded Composite Filler

Abstract

A method and apparatus for forming a composite filler. A composite ply is folded. The composite ply comprises fibers arranged at an angle relative to a central axis of the composite ply such that the composite filler has a varying cross-sectional orientation of fibers. A force is applied to the folded composite ply after folding to form a desired shape for the composite filler.

What is claimed is: 
     
         1 . An apparatus comprising:
 a composite filler including a composite ply having fibers with an orientation at an angle relative to a central axis of the composite ply, wherein the composite ply is folded such that the composite filler has a varying cross-sectional orientation of the fibers.   
     
     
         2 . The apparatus of  claim 1  further comprising:
 a number of composite structures, wherein the composite filler is positioned in a channel formed by the number of composite structures. 
 
     
     
         3 . The apparatus of  claim 1 , wherein a cross-section of the composite filler has a shape that is substantially triangular. 
     
     
         4 . The apparatus of  claim 1 , wherein the composite ply is a single ply of composite prepreg. 
     
     
         5 . The apparatus of  claim 1 , wherein the composite ply is a first composite ply and further comprising:
 a second composite ply, wherein the first composite ply and the second composite ply form a two-ply stack of composite prepreg tape creating a plus-and-minus fiber orientation when folded.   
     
     
         6 . The apparatus of  claim 1 , wherein the composite ply is folded to have an accordion configuration. 
     
     
         7 . A composite filler for a channel comprising:
 a composite ply folded along a first fold line to form a folded composite ply, wherein the first fold line is located along a central axis of the composite ply and the composite ply is folded along a second fold line such that fibers of the folded composite ply have a plus-and-minus fiber orientation along a length of the folded composite ply; and   wherein the composite ply fits within the channel to form the composite filler.   
     
     
         8 . The composite filler of  claim 7 , wherein the composite ply has fibers with an orientation at an angle relative to the central axis of the composite ply such that the composite filler has a varying cross-sectional orientation of the fibers and is formed in a shape of the channel. 
     
     
         9 . The composite filler of  claim 7 , further comprising:
 a number of composite structures, wherein the composite filler is positioned in a channel formed by the number of composite structures; and   wherein the composite filler and the number of composite structures are co-cured.   
     
     
         10 . The composite filler of  claim 7  further comprising:
 an adhesive on an outer surface of the composite filler. 
 
     
     
         11 . The composite filler of  claim 7  further comprising:
 a fabric ply on an inner surface of the channel. 
 
     
     
         12 . The composite filler of  claim 8 , wherein the varying cross-sectional orientation of the fibers in the composite filler reduces at least one of a spread of an inconsistency through the composite filler or a formation of the inconsistency in the composite filler. 
     
     
         13 . The composite filler of  claim 7 , wherein the composite ply is a single ply of composite prepreg tape. 
     
     
         14 . The composite ply of  claim 7 , wherein the composite ply is a first composite ply and further comprising:
 a second composite ply, wherein the first composite ply and the second composite ply form a two-ply stack of composite prepreg tape creating a plus-and-minus fiber orientation when folded.   
     
     
         15 . The composite filler of  claim 7 , wherein a cross-section of the composite filler has a shape that is substantially triangular. 
     
     
         16 . A composite filler comprising:
 a composite ply cut to have desired dimensions, wherein the composite ply is a single ply of composite prepreg tape comprising fibers with an orientation at an angle relative to a central axis of the composite ply;   wherein the composite ply is folded such that the composite filler has a varying cross-sectional orientation of the fibers;   wherein the composite ply has a desired shape for the composite filler;   wherein the composite filler fits in a channel formed by a number of composite structures; and   wherein the composite filler is attached to the number of composite structures.   
     
     
         17 . The composite filler of  claim 16 , wherein the composite filler is co-cured with a number of composite structures. 
     
     
         18 . The composite filler of  claim 16 , wherein the composite filler is co-bonded to a number of composite structures. 
     
     
         19 . The composite filler of  claim 16 , further comprising:
 a first composite ply and a second composite ply, wherein the first composite ply and the second composite ply comprise a two-ply stack of composite prepreg tape creating a plus-and-minus fiber orientation when folded.   
     
     
         20 . The composite filler of  claim 16 , wherein a cross-section of the composite filler has a shape that is substantially triangular.