Polymer-metal composite structural component

Patent metadata

Field	Value
Publication number	US-11168399-B2
Application number	US-201815920391-A
Country	US
Kind code	B2
Filing date	Mar 13, 2018
Priority date	Dec 1, 2014
Publication date	Nov 9, 2021
Grant date	Nov 9, 2021

Abstract

A composite structural component is disclosed. The composite structural component can include a lattice structure, a casing disposed about at least a portion of the lattice structure, and a skin adhered to a surface of the casing. The lattice structure and the casing can be formed of a polymeric material and the skin can be formed of a metallic material. A method of manufacturing a composite structural component is disclosed. The method can include creating a casing of a polymeric material and creating a lattice structure of a polymeric material disposed about at least a portion of the casing. The method can include sealing the porosity of the casing and lattice structure. The method can include adhering a skin of a metallic material to at least a portion of the casing. At least one of creating a lattice structure and creating a casing comprises utilizing an additive manufacturing process.

First claim

What is claimed is:

1. A composite structural component, comprising:
a lattice structure including a plurality of struts exhibiting a three-dimensional geometry and void spaces among the struts;
a casing disposed about at least a portion of the lattice structure, wherein the lattice structure conforms to the casing;
a skin adhered to a surface of the casing; and
a polymeric sealant associated with the casing and the lattice structure,
wherein the lattice structure and the casing are formed of a polymeric material having porosity, and the skin is formed of a metallic material, and
wherein the sealant seals the porosity of the casing and the lattice structure to provide a watertight seal.

2. The composite structural component of claim 1 , wherein the lattice structure and the casing are integrally formed with one another.

3. The composite structural component of claim 1 , wherein the skin comprises a plating on the surface of the casing.

4. The composite structural component of claim 1 , wherein the metallic material comprises nickel.

5. The composite structural component of claim 1 , wherein the casing defines at least one of an exterior and an interior of the composite structural component.

6. The composite structural component of claim 1 , wherein the casing comprises a cylindrical configuration.

7. The composite structural component of claim 1 , further comprising a second casing disposed about at least a portion of the lattice structure opposite the first casing.

8. The composite structural component of claim 7 , wherein a portion of the skin is adhered to a surface of the second casing.

9. The composite structural component of claim 7 , wherein the second casing defines at least one of an exterior and an interior of the composite structural component.

10. The composite structural component of claim 1 , wherein a portion of the skin is adhered to a surface of the lattice structure.

11. A composite structural assembly, comprising:
a first composite structural component and a second composite structural component coupled to one another, each of the first and second composite structural components having
a lattice structure including a plurality of struts exhibiting a three-dimensional geometry and void spaces among the struts;
a casing disposed about at least a portion of the lattice structure;
a skin adhered to a surface of the casing; and
a polymeric sealant associated with the casing and the lattice structure,
wherein the lattice structure and the casing are formed of a polymeric material having porosity, and the skin is formed of a metallic material, and
wherein the sealant seals the porosity of the casing and the lattice structure to provide a watertight seal.

12. The assembly of claim 11 , wherein the first and second composite structural components are coupled to one another with at least one fastener.

13. The assembly of claim 11 , wherein the casings comprise a cylindrical configuration and define an exterior of the composite structural assembly.

14. The assembly of claim 13 , wherein the composite structural assembly forms at least a portion of an unmanned underwater vehicle (UUV) or a missile.

Assignees

• Raytheon Co

Inventors

• Carlsten Curtis B
• Murrow Jonathan
• Item Erik F

Classifications

• F42B10/143 Primary

  Lattice or grid fins · CPC title

• B64C1/00

  Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like · CPC title

• B32B37/16

  with all layers existing as coherent layers before laminating · CPC title

• C23C18/1603

  coating on selected surface areas · CPC title

• F42B12/76

  of the casing · CPC title