Aircraft comprising composite structural component, and method for forming composite structural component

Abstract

A method for fabricating a composite wing structural component for an aircraft is described. The method comprises extruding a filler material into each mold channel of a plurality of mold channels of a die to form a plurality of filler segments, removing the plurality of filler segments from the plurality of mold channels of the die, and arranging the plurality of filler segments in a space in the composite structural component, the space being defined by a radius of the composite structural component, such that the filler segments are in end-to-end contact. The method further comprises curing the plurality of filler segments in the space to fuse the plurality of filler segments.

1 . An aircraft, comprising a fuselage and a wing extending from the fuselage, the aircraft comprising a composite part including
 a flange,   a web,   a radius where the flange and web meet, the radius defining a space therebetween, and   a radius filler located within the space, the radius filler comprising a plurality of filler segments each fused with one or more adjacent filler segments in an end-to-end arrangement.   
     
     
         2 . The aircraft of  claim 1 , wherein the filler segments are fused to the web and the flange to form a unitary structure. 
     
     
         3 . The aircraft of  claim 1 , wherein the composite part comprises a wing stringer. 
     
     
         4 . The aircraft of  claim 3 , wherein the wing stringer comprises a blade stringer. 
     
     
         5 . The aircraft of  claim 4 , further comprising a plurality of wing stringers each comprising a corresponding radius filler. 
     
     
         6 . The aircraft of  claim 1 , wherein each filler segment comprises a length of between eight feet and twelve feet. 
     
     
         7 . The aircraft of  claim 1 , wherein the composite part comprises a carbon fiber composite. 
     
     
         8 . The aircraft of  claim 1 , wherein the radius filler comprises a discontinuous carbon fiber material and a thermoset matrix. 
     
     
         9 . A composite part for an aircraft, the composite part comprising:
 a flange;   a web extending from the flange;   a radius where the flange and web meet, the radius defining a space; and   a radius filler located within the space, the radius filler comprising a plurality of filler segments each fused with one or more adjacent filler segments in an end-to-end manner.   
     
     
         10 . The composite part of  claim 9 , wherein the plurality of filler segments forms a unitary structure. 
     
     
         11 . The composite part of  claim 9 , wherein the composite part comprises a wing stringer. 
     
     
         12 . The composite part of  claim 11 , wherein the wing stringer comprises a blade stringer. 
     
     
         13 . The composite part of  claim 9 , wherein each filler segment comprises a length of between eight and twelve feet. 
     
     
         14 . The composite part of  claim 9 , wherein the composite part comprises a carbon fiber composite. 
     
     
         15 . The composite part of  claim 9 , wherein the composite part comprises a discontinuous carbon fiber material and a thermoset matrix. 
     
     
         16 . A die for forming a radius filler for a composite aircraft wing stringer, the die comprising a plurality of mold channels arranged across a surface of the die, each mold channel shaped to form a radius filler segment for the radius filler. 
     
     
         17 . The die of  claim 16 , wherein the mold channels are angularly offset around a polygonal circumference of the die. 
     
     
         18 . The die of  claim 17 , wherein the die comprises a plurality of flat surfaces, each flat surface holding a mold channel. 
     
     
         19 . The die of  claim 16 , wherein the mold channels are laterally offset across a substantially planar surface of the die. 
     
     
         20 . The die of  claim 16 , wherein each mold channel comprises a length of between eight feet and ten feet.