Composite panel systems and methods

Patent metadata

Field	Value
Publication number	US-11260619-B2
Application number	US-201916394153-A
Country	US
Kind code	B2
Filing date	Apr 25, 2019
Priority date	Apr 25, 2019
Publication date	Mar 1, 2022
Grant date	Mar 1, 2022

Abstract

A composite panel assembly and method of forming the same includes a core, an inner skin coupled to a first side of the core, and an outer skin coupled to a second side of the core. A peripheral edge including portions of the core, the inner skin, and the outer skin, is compressed to close a path into the core.

First claim

What is claimed is:

1. A composite panel assembly, comprising:
a core;
an inner skin coupled to a first side of the core;
a decorative laminate coupled to the inner skin; and
an outer skin coupled to a second side of the core,
wherein a peripheral edge including portions of the core, the inner skin, the decorative laminate, and the outer skin, is compressed.

2. The composite panel assembly of claim 1 , wherein the core is a honeycomb core including a plurality of interconnected honeycomb cells.

3. The composite panel assembly of claim 1 , wherein the inner skin and the outer skin include one or more pre-impregnated epoxy layers.

4. The composite panel assembly of claim 1 , wherein the peripheral edge is rounded.

5. The composite panel assembly of claim 4 , where the portions of the core, the inner skin, the decorative laminate, and the outer skin are rounded in a common direction and orientation.

6. The composite panel assembly of claim 1 , wherein the peripheral edge comprises a bend.

7. The composite panel assembly of claim 1 , wherein the peripheral edge is thinner than a main portion of the composite panel assembly.

8. The composite panel assembly of claim 7 , wherein a closeout spline couples the composite panel assembly to another composite panel assembly.

9. The composite panel assembly of claim 8 , wherein the closeout spline comprises:
an upstanding wall; and
covering ribs coupled to the upstanding wall.

10. The composite panel assembly of claim 9 , wherein a distal end of the peripheral edge is wedged between an interior surface of the upstanding wall and an exterior surface of one of the covering ribs.

11. The composite panel assembly of claim 1 , wherein the portions of each the core, the inner skin, the decorative laminate, and the outer skin, are compressed.

12. A method of forming a composite panel assembly, the method comprising:
providing a core;
coupling an inner skin to a first side of the core;
coupling a decorative laminate to the inner skin;
coupling an outer skin to a second side of the core; and
compressing a peripheral edge including portions of the core, the inner skin, the decorative laminate, and the outer skin.

13. The method of claim 12 , wherein the core is a honeycomb core including a plurality of interconnected honeycomb cells, and wherein the inner skin and the outer skin include one or more pre-impregnated epoxy layers.

14. The method of claim 12 , wherein the compressing comprises rounding the peripheral edge.

15. The method of claim 14 , wherein the rounding comprises rounding the portions of the core, the inner skin, the decorative laminate, and the outer skin in a common direction and orientation.

16. The method of claim 12 , wherein the compressing comprises bending the peripheral edge.

17. The method of claim 12 , further comprising coupling the composite panel assembly to another composite panel assembly with a closeout spline.

18. The method of claim 17 , further comprising wedging a distal end of the peripheral edge between an interior surface of an upstanding wall of the closeout spline and an exterior surface of a covering rib of the closeout spline.

19. A composite panel system, comprising:
a first composite panel assembly; and
a second composite panel assembly, wherein each of the first composite panel assembly and the second composite panel assembly comprises:
a core;
an inner skin coupled to a first side of the core;
a decorative laminate coupled to the inner skin; and
an outer skin coupled to a second side of the core,
wherein a peripheral edge including portions of the core, the inner skin, the decorative laminate, and the outer skin, is compressed.

20. The composite panel system of claim 19 , wherein the first composite panel assembly is separated from the second composite panel assembly by a gap.

21. The composite panel system of claim 20 , further comprising a closeout spline that couples the first composite panel assembly to the second composite panel assembly, wherein the closeout spline comprises:
an upstanding wall; and
covering ribs coupled to the upstanding wall, a distal end each of the peripheral edges is wedged between an interior surface of the upstanding wall and exterior surface of one of the covering ribs.

Assignees

• Boeing Co

Inventors

• Switzer Lon E

Classifications

• B64C1/00

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

• B32B2038/0024

  Crushing · CPC title

• B32B37/144

  using layers with different mechanical or chemical conditions or properties, e.g. layers with different thermal shrinkage, layers under tension during bonding (constructional features for tensioning B32B38/1825) · CPC title

• B32B37/182

  one or more of the layers being plastic · CPC title

• B32B2260/046

  Synthetic resin · CPC title