US 12,311,620 B2
Composite parts, and methods of manufacturing
Andi Meyer, Wichita, KS (US); Mark Anthony Wadsworth, Wichita, KS (US); and Ronald Jones, Wichita, KS (US)
Assigned to Spirit AeroSystems, Inc., Wichita, KS (US)
Filed by Spirit AeroSystems, Inc., Wichita, KS (US)
Filed on Mar. 17, 2023, as Appl. No. 18/122,830.
Prior Publication US 2024/0308159 A1, Sep. 19, 2024
Int. Cl. B29C 70/84 (2006.01); B29K 105/08 (2006.01); B29L 31/30 (2006.01)
CPC B29C 70/845 (2013.01) [B29K 2105/0881 (2013.01); B29L 2031/3076 (2013.01)] 12 Claims
OG exemplary drawing
 
1. A method of manufacturing a composite part, the method comprising:
forming an initial radius filler on a composite panel, wherein the initial radius filler is formed from a plurality of plies of composite material stacked on the composite panel;
forming a radius of curvature on at least one side of the initial radius filler;
positioning a composite stiffener on the composite panel, wherein the composite stiffener is contoured to define a radius gap when joined with the composite panel;
positioning the composite stiffener against the at least one side of the initial radius filler;
compressing the composite panel and the composite stiffening member together via consolidation pressure; and
heating the initial radius filler to at least one of a cure temperature, a melting temperature, or a fusing temperature to form, from the initial radius filler, a radius gap filler in the radius gap;
wherein forming the radius of curvature includes size-reducing the at least one side of the initial radius filler.