Composite core structure and method

Patent metadata

Field	Value
Publication number	US-2017190851-A1
Application number	US-201615391342-A
Country	US
Kind code	A1
Filing date	Dec 27, 2016
Priority date	Dec 30, 2015
Publication date	Jul 6, 2017
Grant date	—

Abstract

A composite core structure includes a core having a plurality of elongated fibers and a plurality of spherical members, the elongated fibers and spherical members consolidated into a desired molded shape. The composite core structure also includes a matrix material encapsulating the elongated fibers and spherical members.

First claim

What is claimed is:

1 . A composite core structure comprising:
a core having a plurality of elongated fibers and a plurality of spherical members, the elongated fibers and spherical members consolidated into a desired molded shape; and a matrix material encapsulating the elongated fibers and spherical members.

2 . The composite structure of claim 1 , wherein the spherical members are hollow.

3 . The composite structure of claim 1 , wherein the plurality of elongated fibers includes a plurality of lengths.

4 . The composite structure of claim 1 , wherein the spherical members are formed of thermoplastic.

5 . The composite structure of claim 1 , wherein the elongated fibers are formed of carbon fiber.

6 . A slurry for forming a composite core structure comprising:
a suspension medium; a plurality of elongated fibers disposed in the suspension medium; and a plurality of spherical members disposed in the suspension medium.

7 . The slurry of claim 6 , wherein the suspension medium is a fluid.

8 . The slurry of claim 6 , wherein the spherical members are hollow.

9 . The composite structure of claim 6 , wherein the plurality of elongated fibers includes a plurality of lengths.

10 . The composite structure of claim 6 , wherein the spherical members are formed of thermoplastic.

11 . The composite structure of claim 6 , wherein the elongated fibers are formed of carbon fiber.

12 . A method of forming a composite core structure comprising:
providing a slurry comprising a suspension medium, a plurality of elongated fibers disposed in the suspension medium, and a plurality of hollow spherical members disposed in the suspension medium; drawing the slurry into a mold form with a porous base; filtering the suspension medium out of the mold form through the porous base; consolidating the elongated fibers and the hollow spherical members; infusing a matrix material into the mold form for mixing with the elongated fibers and the hollow spherical members; and hardeneing the matrix material, elongated fibers and hollow spherical members into a structure.

13 . The method of claim 12 , wherein the structure is a monolithic structure.

14 . The method of claim 12 , wherein the elongated fibers and the hollow spherical members are consolidated in the mold form under vacuum.

15 . The method of claim 12 , further comprising customizing the structural properties of the composite core structure based on modification of at least one structural factor.

16 . The method of claim 15 , wherein the at least one structural factor comprises at least one of density or strength of the elongated fibers, size of the hollow spherical members and constituent materials.

17 . The method of any of claim 12 , further comprising removing any residue of the suspension medium through a flushing process after consolidation.

Assignees

• Sikorsky Aircraft Corp

Inventors

• Garhart Jonathan K

Classifications

• B29C51/10

  Forming by pressure difference, e.g. vacuum · CPC title

• B29L2031/731

  Filamentary material, i.e. comprised of a single element, e.g. filaments, strands, threads, fibres (cables B29L2031/707) · CPC title

• C08K7/22

  Expanded, porous or hollow particles · CPC title

• B29C70/025

  with particular filler · CPC title

• C08J5/042 Primary

  with carbon fibres · CPC title