Advanced composite heated floor panel

Patent metadata

Field	Value
Publication number	US-11040765-B2
Application number	US-201816135265-A
Country	US
Kind code	B2
Filing date	Sep 19, 2018
Priority date	Jun 27, 2018
Publication date	Jun 22, 2021
Grant date	Jun 22, 2021

Abstract

A composite panel suitable for heating an environment includes a face sheet having a 3D woven structure and abutting the environment, and a first core layer positioned on a side of the face sheet opposite the environment. The 3D woven structure includes at least one z-fiber extending in a first direction, the first direction representing a thickness of the face sheet. The woven structure further includes a plurality of weft layers, each having a weft fiber extending in a second direction, and a warp layer disposed between the plurality of weft layers, the warp layer having a warp fiber extending in a third direction. The z-fiber extends along the plurality of weft layers across a full extent of the 3d woven structure in the first direction.

First claim

The invention claimed is:

1. A composite panel suitable for heating an environment, the panel comprising:
a face sheet abutting the environment and comprising a 3D woven structure, the 3D woven structure comprising:
at least one z-fiber extending in a first direction, the first direction representing a thickness of the face sheet;
a plurality of weft layers, each of the weft layers comprising a weft fiber extending in a second direction;
a warp layer disposed between the plurality of weft layers, the warp layer comprising a warp fiber extending in a third direction;
wherein the at least one z-fiber extends along the plurality of weft layers across a full extent of the 3D woven structure in the first direction;

a first core layer positioned on a side of the face sheet opposite the environment, the first core layer comprising a high-density honeycomb core formed from aluminum; and
a second core layer disposed on a side of the first core layer opposite the face sheet, the second core layer comprising one of a polymer foam and a polymer honeycomb.

2. The panel of claim 1 , wherein the at least one z-fiber is formed from a glass, aramid, or metallic material.

3. The panel of claim 1 , wherein the at least one z-fiber comprises a nanostructure formed from steel nanotubes or carbon nanotubes.

4. The panel of claim 1 , wherein the at least one z-fiber comprises a plurality of z-fibers.

5. The panel of claim 1 , wherein the weft fiber is formed from a glass, aramid, or metallic material.

6. The panel of claim 1 , wherein the warp fiber is formed from a glass, aramid, or metallic material.

7. The panel of claim 1 , wherein the face sheet further comprises a matrix formed from a thermoset or thermoplastic material.

8. The panel of claim 7 , wherein the z-fiber has a higher thermal conductivity than the matrix.

9. The panel of claim 1 , wherein the first, second, and third directions are orthogonal to one another.

10. The panel of claim 1 and further comprising: a first reinforcing layer abutting the first core layer, and a second reinforcing layer abutting the second core layer.

11. The panel of claim 1 , wherein the environment is an aircraft compartment.

12. A method of forming a composite panel suitable for heating an environment, the method comprising:
positioning a face sheet in communication with the environment, the face sheet comprising a 3D woven structure; the 3D woven structure comprising:
at least one z-fiber extending in a first direction, the first direction representing a thickness of the face sheet;
a plurality of weft layers, each of the weft layers comprising a weft fiber extending in a second direction;
a warp layer disposed between the plurality of weft layers, the warp layer comprising a warp fiber extending in a third direction;
wherein the at least one z-fiber extends along the plurality of weft layers across a full extent of the 3D woven structure in the first direction;

positioning a first core layer on a side of the face sheet opposite the environment, the first core layer comprising a high-density honeycomb core formed from aluminum; and
positioning a second core layer on a side first core layer opposite the face sheet, the second core layer comprising one of a polymer foam and a polymer honeycomb.

13. The method of claim 12 , wherein the at least one z-fiber is formed from a glass, aramid, or metallic material.

14. The method of claim 12 , wherein the at least one z-fiber comprises a nanostructure formed from steel nanotubes or carbon nanotubes.

15. The method of claim 12 , wherein the weft fiber and the warp fiber are formed from a glass, aramid, or metallic material.

16. The method of claim 12 , wherein the face sheet further comprises a matrix formed from a thermoset or thermoplastic material.

Assignees

• Goodrich Corp

Inventors

• Krishnappa Aruna Kumar Huluvangala
• Mahapatra Guru Prasad

Classifications

• D10B2401/16

  antistatic; conductive · CPC title

• D10B2101/06

  Glass · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title

• B32B5/26

  another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} · CPC title

• B32B2471/00

  Floor coverings (B32B2419/04 takes precedence) · CPC title