Composite structure and core positioning ply

Patent metadata

Field	Value
Publication number	US-9539769-B2
Application number	US-201113274690-A
Country	US
Kind code	B2
Filing date	Oct 17, 2011
Priority date	Oct 17, 2011
Publication date	Jan 10, 2017
Grant date	Jan 10, 2017

Abstract

A composite structure includes a first laminate, a second laminate, and at least one core component located between the first laminate and the second laminate. The at least one core component includes a honeycomb core and at least one locking ply extending from the honeycomb core between the first laminate and the second laminate. The at least one locking ply is configured such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.

First claim

The invention claimed is:

1. A method of forming a composite structure comprising:
positioning a first laminate in a molding tool;
co-curing at least one locking ply to a honeycomb core element;
positioning the honeycomb core element and the at least one locking ply co-cured to the honeycomb core element in the molding tool;
positioning a second laminate over the core element, wherein the at least one locking ply extends outwardly from said honeycomb core element such that a portion of the at least one locking ply is positioned directly between the first laminate and the second laminate; and
applying pressure to the second laminate thereby retaining the at least one locking ply between the first laminate and the second laminate and preventing movement of the core element.

2. The method of claim 1 , wherein the at least one locking ply is two or more locking plies.

3. The method of claim 1 , wherein the at least one locking ply is one of a prepreg or wet layup material.

4. The method of claim 1 , wherein the at least one locking ply is retained directly between the first laminate and the second laminate.

5. The method of claim 1 , wherein the pressure is about 65 psi.

Assignees

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

Inventors

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

Classifications

• Y10T428/24149

  Honeycomb-like · CPC title

• B29C70/30

  Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core · CPC title

• B32B3/12

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

• B29C66/1142

  Single butt to butt joints · CPC title

• B29C65/00

  Joining {or sealing} of preformed parts {, e.g. welding of plastics materials}; Apparatus therefor {(general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326)} · CPC title