Composite honeycomb structure

Patent metadata

Field	Value
Publication number	US-9296044-B2
Application number	US-201113095558-A
Country	US
Kind code	B2
Filing date	Apr 27, 2011
Priority date	Aug 18, 2006
Publication date	Mar 29, 2016
Grant date	Mar 29, 2016

Abstract

Adjoining edges of adjacent honeycomb core panel sections are mechanically interlocked. In one embodiment, the method includes forming a first edge along a first cellular core panel section. The first edge includes a first plurality of edge cell walls along the first edge. The method further includes forming a second edge along a second cellular core panel section, wherein the second edge includes a second plurality of edge cell walls along the second edge. The first edge is positioned proximate to the second edge. At least a portion of at least one of the first plurality of edge cell walls is mechanically interlocked with at least a portion of at least one of the second plurality of edge cell walls to form a joint therebetween. The invention also includes a composite structure at least partially produced by such a method.

First claim

What is claimed is:

1. A composite structure comprising:
a first cellular core section having a first edge with a first plurality of edge cell walls along the first edge;
a second cellular core section having a second edge with a second plurality of edge cell walls along the second edge,
wherein the second edge faces and opposes the first edge;
wherein the first plurality of edge cell walls face the second plurality of cell edge walls, and
wherein a first portion of an edge cell wall of the first plurality of edge cell walls is plastically deformed to mechanically interlock with a second portion of an edge cell wall of the second plurality of edge cell walls, thereby forming a fixed joint therebetween, the first portion being continuous with the edge cell wall of the first plurality of edge cell walls and the second portion being continuous with the edge cell wall of the second plurality of edge cell walls.

2. The composite structure according to claim 1 , wherein the first portion comprises a first hook portion, the second portion comprises a second hook portion, and the first and second hook portions are at least partially interlocked with each other.

3. The composite structure according to claim 1 , wherein the first portion comprises a first double hook portion, the second portion comprises a second double hook portion, and the first and second double hook portions are at least partially interlocked with each other.

4. The composite structure according to claim 1 , wherein the edge cell wall including the first portion and the edge cell wall including the second portion comprise metal foil.

5. The composite structure according to claim 1 , wherein the joint is disposed between a first cell having a first volume and a second cell having a second volume, and wherein the joint occupies substantially none of the first volume or the second volume.

6. The composite structure according to claim 1 , further comprising:
at least one imperforate backing sheet on the first and second cellular core sections; and
at least one air permeable face sheet on the first and second cellular core sections.

7. The composite structure according to claim 1 , wherein portions of at least two of the first plurality of edge cell walls are mechanically interlocked with portions of at least two of the second plurality of edge cell walls.

Assignees

• Douglas Alan Richard
• Rohr Inc

Inventors

• Douglas Alan Richard

Classifications

• F16B5/01

  by means of fastening elements specially adapted for honeycomb panels · CPC title

• B32B3/12 Primary

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

• B23B3/12 Primary

  with the faceplate vertical, i.e. face lathes · CPC title

• B64D2033/0206

  comprising noise reduction means, e.g. acoustic liners · CPC title

• B32B3/18

  characterised by an internal layer formed of separate pieces of material {which are juxtaposed side-by-side (B32B5/02 takes precedence)} · CPC title