Composite panel including a tailored composite core via additive manufacturing

Patent metadata

Field	Value
Publication number	US-2023398762-A1
Application number	US-202217836056-A
Country	US
Kind code	A1
Filing date	Jun 9, 2022
Priority date	Jun 9, 2022
Publication date	Dec 14, 2023
Grant date	—

Abstract

A composite panel comprises a first skin and a second skin. A core is arranged between and attached to the first skin and the second skin. The core includes Z zones that are 3D printed using a thermoplastic material. Each of the Z zones abuts and is connected to another one of the Z zones. Each of the Z zones has one of D densities and at least one of the Z zones had a different density that another one of the Z zones. Z and D are integers greater than one.

First claim

1 . A composite panel comprising:
a first skin; a second skin; and a core arranged between and attached to the first skin and the second skin, wherein the core includes at least one layer of Z zones that are 3D printed using a thermoplastic material, wherein each of the Z zones abuts and is connected to another one of the Z zones, wherein each of the Z zones has one of D densities and at least one of the Z zones has a different density that another one of the Z zones, wherein each of the Z zones includes an infill pattern having paths along borders between abutting ones of the Z zones having different densities, wherein the paths between abutting ones of the Z zones having different densities are located in overlap regions, wherein the overlap regions are discontinuous along the borders, and where Z and D are integers greater than one.

2 . The composite panel of claim 1 , wherein each the infill pattern of each of the Z zones includes a repeating infill shape having a predetermined size.

3 . The composite panel of claim 2 , wherein the repeating infill shape includes triangles.

4 . The composite panel of claim 1 , wherein the thermoplastic material includes embedded fibers selected from a group consisting of glass fiber, aramid fiber, natural fiber, carbon fiber and combinations thereof.

5 . The composite panel of claim 1 , further comprising connection locations that are integrated with the core.

6 - 8 . (canceled)

9 . The composite panel of claim 1 , further comprising:
openings defined in printed portions of the composite panel in planar regions of the composite panel; and planar core members bonded in the openings.

10 . The composite panel of claim 1 , further comprising:
a plurality of joining sections printed in the core; and a susceptor layer arranged between the plurality of joining sections and at least one of the first skin and the second skin, wherein the at least one of the first skin and the second skin is inductively heated to bond the susceptor layer and the plurality of joining sections of the core.

11 . A method for making a composite panel comprising:
modelling expected loads on a composite panel during use, wherein the composite panel includes a core arranged between and attached to a first skin and a second skin; identifying locations of Z zones in the core, wherein each of the Z zones includes a border abutting and connected to another one of the Z zones; and 3D printing the Z zones using a thermoplastic material, wherein each of the Z zones has one of D densities and at least one of the Z zones has a different density that another one of the Z zones, wherein each of the Z zones includes an infill pattern having paths along borders between abutting ones of the Z zones having different densities, wherein the paths between abutting ones of the Z zones having different densities are located in overlap regions, wherein the overlap regions are discontinuous along the borders, and where Z and D are integers greater than one.

12 . The method of claim 11 , wherein the infill pattern of each of the Z zones includes a repeating infill shape having a predetermined size.

13 . The method of claim 12 , wherein the repeating infill shape includes triangles.

14 . The method of claim 11 , wherein the thermoplastic material includes embedded fibers selected from a group consisting of glass fiber, aramid fiber, natural fiber, carbon fiber and combinations thereof.

15 . The method of claim 11 , further comprising integrating connection locations into the core.

16 - 18 . (canceled)

19 . The method of claim 11 , further comprising:
arranging openings in the composite panel in planar regions of the composite panel; and bonding planar core members in the openings.

20 . The method of claim 11 , further comprising:
printing a plurality of joining sections in the core; arranging a susceptor layer between the plurality of joining sections and at least one of the first skin and the second skin; and using inductive heating to bond the at least one of the first skin and the second skin to the susceptor layer and the plurality of joining sections of the core.

Assignees

• Gm Global Tech Operations Llc
• Pratt & Miller Eng And Fabrication Inc

Inventors

• Gergely Ryan
• Latham Gary Alan
• Cunningham Andrew Thomas
• Okonski David A

Classifications

• B32B3/12 Primary

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

• B32B37/06

  characterised by the heating method · CPC title

• B32B37/26

  with at least one layer which influences the bonding during the lamination process, e.g. release layers or pressure equalising layers · CPC title

• B33Y10/00

  Processes of additive manufacturing · CPC title

• B33Y80/00

  Products made by additive manufacturing · CPC title