Composite panels and methods for manufacturing the same

Patent metadata

Field	Value
Publication number	US-2024253333-A1
Application number	US-202318162940-A
Country	US
Kind code	A1
Filing date	Feb 1, 2023
Priority date	Feb 1, 2023
Publication date	Aug 1, 2024
Grant date	—

Abstract

A method of assembling a composite panel includes disposing a pliable matrix material between a first side of a ceramic core structure and a ceramic matrix composite face sheet, wherein the ceramic core structure comprises a plurality of hollow cells defined by a plurality of walls extending from the first side of the ceramic core structure to a second side of the ceramic core structure opposite the first side; and densifying the pliable matrix material to bond the pliable matrix material with the ceramic core structure and the ceramic matrix composite face sheet.

First claim

We claim:

1 . A method of assembling a composite panel, the method comprising:
disposing a pliable matrix material between a first side of a ceramic core structure and a ceramic matrix composite face sheet, wherein the ceramic core structure comprises a plurality of hollow cells defined by a plurality of walls extending from the first side of the ceramic core structure to a second side of the ceramic core structure opposite the first side; and densifying the pliable matrix material to bond the pliable matrix material with the ceramic core structure and the ceramic matrix composite face sheet.

2 . The method of claim 1 , wherein the pliable matrix material comprises a liquid carrier, a powder, and a polymeric binder.

3 . The method of claim 2 , wherein the powder comprises 10 percent to 90 percent carbon by weight.

4 . The method of claim 2 , wherein the powder comprises carbon and silicon carbide.

5 . The method of claim 4 , wherein the powder comprises 45 percent to 55 percent carbon by weight and 45 percent to 55 percent silicon carbide by weight.

6 . The method of claim 2 , wherein the liquid carrier comprises 50% to 70% by volume of the pliable matrix material.

7 . The method of claim 1 , wherein the pliable matrix material comprises a pliable matrix material paste.

8 . The method of claim 7 , wherein the pliable matrix material forms a fillet between the ceramic matrix composite face sheet and the ceramic core structure.

9 . The method of claim 1 , wherein the pliable matrix material comprises a pliable matrix material ply.

10 . The method of claim 1 , wherein densifying the pliable matrix material comprises densifying via melt infiltration.

11 . The method of claim 10 , wherein a densifying material is silicon, germanium, boron, or combinations thereof.

12 . The method of claim 1 , wherein densifying the pliable matrix material comprises densifying via chemical vapor infiltration.

13 . The method of claim 1 , wherein densifying the pliable matrix material comprises densifying via polymer infiltration and pyrolysis.

14 . The method of claim 1 , further comprising additively manufacturing the ceramic core structure.

15 . The method of claim 1 , wherein the plurality of walls are unitarily and monolithically formed to define the plurality of hollow cells.

16 . The method of claim 1 , further comprising disposing the pliable matrix material between the second side of the ceramic core structure and a ceramic matrix composite back sheet; and
densifying the pliable matrix material to bond the pliable matrix material with the ceramic core structure and the ceramic matrix composite back sheet.

17 . A composite panel comprising:
a ceramic core structure comprising a plurality of hollow cells defined by a plurality of walls extending from a first side of the ceramic core structure to a second side of the ceramic core structure, the second side opposite the first side; a ceramic matrix composite face sheet disposed at the first side of the ceramic core structure; and a matrix material that is densified and bonded with both the ceramic core structure and the ceramic matrix composite face sheet.

18 . The composite panel of claim 17 , wherein the matrix material comprises silicon carbide.

19 . The composite panel of claim 17 , further comprising:
a ceramic matrix composite back sheet disposed at the second side of the ceramic core structure; and additional matrix material that is densified and bonded to both the ceramic core structure and the ceramic matrix composite back sheet.

20 . A composite panel comprising:
an additively-manufactured ceramic core structure comprising a plurality of hollow cells defined by a plurality of walls extending from a top face to a bottom face; a ceramic matrix composite face sheet; and a conformal interface layer bonding the top face of the additively-manufactured ceramic core structure to the ceramic matrix composite face sheet.

Assignees

• Gen Electric

Inventors

• Dunn Daniel Gene
• Mcguigan Henry Charles
• Sarrafi-Nour Reza

Classifications

• B32B33/00

  Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class · CPC title

• B32B9/04

  comprising such {particular} substance 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 glass layer B32B17/06; layered products with at least two ceramic layers composed mainly of ceramic B32B18/00)} · CPC title

• B32B9/005 Primary

  comprising one layer of ceramic material, e.g. porcelain, ceramic tile (layered products with at least two ceramic layers composed mainly of ceramic B32B18/00) · CPC title

• F02K1/827

  Sound absorbing structures or liners · CPC title

• C04B2237/086

  Carbon interlayers · CPC title