Composite vehicle body

Patent metadata

Field	Value
Publication number	US-10787240-B2
Application number	US-201715697483-A
Country	US
Kind code	B2
Filing date	Sep 7, 2017
Priority date	Nov 3, 2016
Publication date	Sep 29, 2020
Grant date	Sep 29, 2020

Abstract

A vehicle body may have a skeleton formed by a plurality of overlapping layers bonded to each other. Each of the plurality of overlapping layers may be fabricated from a continuous fiber coated with a matrix material. A trajectory of the continuous fiber may be different between adjacent layers of the plurality of overlapping layers.

First claim

What is claimed is:

1. A vehicle body, comprising a skeleton formed by a plurality of overlapping layers bonded to each other, each of the plurality of overlapping layers being fabricated from a continuous fiber coated with a matrix material, wherein a trajectory of the continuous fiber is different between adjacent layers of the plurality of overlapping layers; further including a skin formed over the skeleton from a continuous fiber sheet coated with a matrix material, wherein the matrix material of the skin is different from the matrix material of the skeleton.

2. The vehicle body of claim 1 , wherein the plurality of overlapping layers includes:
a first type of layer forming an open-center perimeter of a cross-section of the skeleton; and
a second type of layer forming a cross-section of the skeleton having a perimeter and cross-pieces between nodes in the perimeter.

3. The vehicle body of claim 2 , wherein the first type of layer alternates with the second type of layer in the plurality of overlapping layers.

4. The vehicle body of claim 2 , wherein the plurality of overlapping layers includes a set of the second type of layer that is repeated.

5. The vehicle body of claim 4 , wherein the set includes three different patterns of the second type of layer.

6. The vehicle body of claim 5 , wherein each of the three different patterns of the set includes segments of a perimeter of the cross-section of the skeleton, the segments from the three different patterns of the set together completing the perimeter.

7. The vehicle body of claim 6 , wherein the segments each of the three different patterns are about ⅓ to ⅙ of a length of the cross-section.

8. The vehicle body of claim 2 , wherein the cross-pieces forms an angle of about 25-65° relative to a support surface of the perimeter of the cross-section.

9. The vehicle body of claim 8 , wherein the cross-pieces of the plurality of overlapping layers forms at least one complete “X” at a center of the cross-section of the skeleton.

10. The vehicle body of claim 1 , wherein each of the plurality of overlapping layers includes:
an inner lap forming the skeleton; and
an outer lap forming the skin over the skeleton.

11. The vehicle body of claim 1 , wherein each of the plurality of overlapping layers is formed by a middle-out tool path of the continuous fiber.

12. A vehicle body, comprising a skeleton formed by a plurality of overlapping layers bonded to each other, each of the plurality of overlapping layers being fabricated from a continuous fiber coated with a matrix material, wherein a trajectory of the continuous fiber is different between adjacent layers of the plurality of overlapping layers;
wherein the skeleton has a wing shape; and
wherein each of the plurality of overlapping layers forms a rib cross-section of the wing.

13. A vehicle body, comprising:
a skeleton formed by a plurality of overlapping layers bonded to each other, each of the plurality of overlapping layers being fabricated from a continuous fiber coated with a matrix material; and
a skin formed over the skeleton from a continuous fiber sheet coated with a matrix material,
wherein the plurality of overlapping layers includes:
a first type of layer forming an open-center perimeter of a cross-section of the skeleton;
a second type of layer forming a cross-section of the skeleton having a perimeter and cross-pieces between nodes in the perimeter; and
the first type of layer alternates with the second type of layer in the plurality of overlapping layers.

14. The vehicle body of claim 13 , wherein the plurality of overlapping layers includes a set of the second type of layer that is repeated.

15. The vehicle body of claim 14 , wherein the set includes three different patterns of the second type of layer.

16. The vehicle body of claim 15 , wherein each of the three different patterns of the set includes segments of a perimeter of the cross-section of the skeleton, the segments from the three different patterns of the set together completing the perimeter.

17. The vehicle body of claim 16 , wherein the cross-pieces of the plurality of overlapping layers forms at least one complete “X” at a center of the cross-section of the skeleton.

18. A vehicle body, comprising:
an internal skeleton including a rib having opposing support surfaces, opposing braces, and cross-pieces connecting the opposing support surfaces and opposing braces, wherein the opposing support surfaces, opposing braces, and cross-pieces are formed by at least one continuous fiber using a middle-out tool path; and
a skin formed over the internal skeleton, the skin including:
a matrix material;
a plurality of continuous fibers encased within the matrix material and arranged in layers generally parallel to a surface of the vehicle body.

Assignees

• Cc3D Llc
• Continuous Composites Inc

Inventors

• Tyler Kenneth L

Classifications

• B29C70/302

  Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination · CPC title

• B29L2031/3082

  Fuselages · CPC title

• B64C3/18

  Spars; Ribs; Stringers · CPC title

• B29C70/0035

  comprising two or more matrix materials · CPC title

• B29C70/16

  using fibres of substantial or continuous length {(non-woven fabrics per se D04H3/00)} · CPC title