Large cell carbon core sandwich panel and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-11712871-B2
Application number	US-202017109076-A
Country	US
Kind code	B2
Filing date	Dec 1, 2020
Priority date	Jan 23, 2018
Publication date	Aug 1, 2023
Grant date	Aug 1, 2023

Abstract

A method of fabricating a panel includes laying up a first laminate on a tooling surface, laying a first layer of thermoplastic on an inner surface of the first laminate, laying a large cell carbon core on the first layer of thermoplastic, laying a second layer of thermoplastic across the large cell carbon core, laying a second laminate on the second layer of thermoplastic, creating a sealed core pocket by bonding the edges of the first and second layers of the thermoplastic surrounding a perimeter of the core, increasing pressure within the core pocket, increasing pressure on the outer surface of the second laminate, heating the panel to a desired curing temperature, and maintaining the increased pressures and temperature for a desired curing duration.

First claim

What is claimed is:

1. A panel, comprising:
a first laminate having an outer surface, an inner surface, and a depth extending from the outer surface to the inner surface;
a core having a first side and an opposite second side, the core defining a plurality of cells extending from the first side to the opposite second side, each cell being separated from each adjacent cell by a permeable cell wall, each cell having a height measured from the first side to the opposite second side and a width perpendicular to the height, the width of each cell being at least ½ of an inch;
a first layer of thermoplastic located between, and bonded to, the inner surface of the first laminate and the first side of the core;
a second laminate having an outer surface, an inner surface, and a depth extending from the outer surface to the inner surface; and
a second layer of thermoplastic located between, and bonded to, the inner surface of the second laminate and the opposite second side of the core;
wherein one of the first laminate or the second laminate includes a port extending from the outer surface to the inner surface thereof and wherein the port and an associated one of the plurality of cells is filled with sealant.

2. The panel of claim 1 , wherein the port has a diameter that is less than the width of one of the cells.

3. The panel of claim 2 , wherein the port is positioned over a single one of the cells so the port does not intersect with any of the cell walls.

4. The panel of claim 2 , wherein the port includes a threaded opening.

5. The panel of claim 4 , further comprising a cap sealing the port.

6. The panel of claim 5 , wherein the height of the cells is greater than the depth of the first laminate and the depth of the second laminate.

7. The panel of claim 6 , wherein the depth of the first laminate is different than the depth of the second laminate.

Assignees

• Textron Innovations Inc

Inventors

• Kooiman James Everett
• Carlson David
• Wolfe Douglas K
• Freeman Jonathan Alexander

Classifications

• B32B3/266 Primary

  characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12 · CPC title

• B29C70/342

  using isostatic pressure · CPC title

• B32B3/12

  characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure · CPC title

• B32B27/06

  as the main or only constituent of a layer, {which is} next to another layer of {the same or of} a {different material (next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} · CPC title

• B32B37/1009

  using vacuum and fluid pressure · CPC title