Composite structure core crush prevention

Patent metadata

Field	Value
Publication number	US-9409358-B2
Application number	US-201213651914-A
Country	US
Kind code	B2
Filing date	Oct 15, 2012
Priority date	Oct 15, 2012
Publication date	Aug 9, 2016
Grant date	Aug 9, 2016

Abstract

A composite structure includes a first laminate and a second laminate. At least one core assembly is located between the first laminate and the second laminate. The at least one core assembly includes a core component and a layer of filler material disposed at a first face of the core component. The layer of filler material at least partially fills selected cells of the core component to a fill depth such that the filler material rigidizes when cured to prevent movement and/or crushing of core component under a pressure applied during a cure cycle of the composite structure.

First claim

The invention claimed is:

1. A composite structure comprising:
a core assembly including:
a core component having a plurality of core cells; and
a layer of rigidized filler material disposed at a first face of the core component at least partially filling selected cells of the core component to a fill depth, the filler material being arrayed in one or more contiguous filled strips extending across two or more cells of the core component and configured to prevent movement and/or crushing of the core component under a pressure applied in a direction substantially perpendicular to a thickness of the core component;

a first laminate; and
a layer of adhesive to secure the first laminate to the core assembly.

2. The composite structure of claim 1 , wherein the filler material is rigidized in the selected cells via pre-curing with the core component.

3. The composite structure of claim 1 , wherein the filler material is disposed at the first face and a second face opposite the first face of the core component.

4. The composite structure of claim 1 , wherein the one or more filler strips are oriented at a nonparallel angle to a width of the composite structure.

5. The composite structure of claim 4 , wherein the angle is about 45 degrees.

6. The composite structure of claim 1 , wherein the filler material is a glass filled epoxy material.

7. The composite structure of claim 1 , wherein the fill depth is between about 10% and about 50% of a core component thickness.

8. The composite structure of claim 1 , wherein the fill depth equals a core component thickness.

9. A composite structure comprising:
a core assembly including:
a core component having a plurality of core cells; and
a layer of rigidized filler material disposed at a first face of the core component at least partially filling selected cells of the core component to a fill depth, the filler material configured to prevent movement and/or crushing of the core component under a pressure applied in a direction substantially perpendicular to a thickness of the core component, the filler material arrayed in one or more contiguous filler strips extending across two or more cells of the plurality of core cells, the one or more filler strips oriented at a nonparallel angle to a width of the composite structure, the fill depth between about 10% and about 50% of a core component thickness;

a first laminate; and
a layer of adhesive to secure the first laminate to the core assembly.

Assignees

• Bremmer Jonathan
• Toni Darryl Mark
• Sauer Jeffrey G
• Fabian Edward Joseph
• Denavit Paul H
• Hovan Iii William E
• Davidson Gregory A
• Sikorsky Aircraft Corp

Inventors

• Bremmer Jonathan
• Toni Darryl Mark
• Sauer Jeffrey G
• Fabian Edward Joseph
• Denavit Paul H
• Hovan Iii William E
• Davidson Gregory A

Classifications

• Y10T428/24157

  Filled honeycomb cells [e.g., solid substance in cavities, etc.] · CPC title

• B29D99/0021

  provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix · CPC title

• Y10T156/10

  Methods of surface bonding and/or assembly therefor · CPC title

• B29D24/005 Primary

  the structure having joined ribs, e.g. honeycomb · CPC title

• E04C2/365

  by honeycomb structures · CPC title