Composite core and method of making same

Patent metadata

Field	Value
Publication number	US-9713913-B2
Application number	US-201113260690-A
Country	US
Kind code	B2
Filing date	Feb 4, 2011
Priority date	Feb 4, 2010
Publication date	Jul 25, 2017
Grant date	Jul 25, 2017

Abstract

A composite core includes a plurality of tubes, each the plurality of tubes comprising a plurality of fibers disposed in a polymeric matrix. Adjacent tubes of the plurality of tubes are adhesively bonded to one another along sides of the adjacent tubes. A method of making a composite core includes the steps of providing a plurality of tubes, each of the plurality of tubes including a plurality of fibers disposed in a polymeric matrix, and adhesively bonding adjacent tubes of the plurality of tubes along sides of the adjacent tubes. A method of making a composite core such that a removable band is included in the core, the removable band being configured to be removable through a procedure subsequent to the cure of the composite core, thereby producing gaps in the core.

First claim

The invention claimed is:

1. A composite core, comprising:
a first tube and a second tube, the first tube and the second tube having a plurality of fibers woven with a plurality of removable bands and disposed in a polymeric matrix, wherein at least some of the plurality of removable bands are woven with others of the plurality of removable bands to produce a weave pattern; and
a first end portion of each of the first tube and the second tube being configured to support a first face sheet and a second end portion of each of the first tube and the second tube being configured to support a second face sheet;
wherein the plurality of fibers of each of the first tube and the second tube are in contact with each other to form a cross-linked pattern, which in turn secures the first tube to the second tube via the plurality of fibers; and
wherein the plurality of fibers of each tube are arranged in a uniaxial configuration so as to be arranged in a single direction, such that the plurality of fibers of each tube crosslink with fibers of adjacent tubes, the crosslinking being generated even though each tube has a plurality of fibers only in a single direction.

2. The composite core, according to claim 1 , wherein the plurality of fibers of the first tube and the second tube have been wound in a single helical direction to form each tube.

3. The composite core, according to claim 1 , wherein the first tube has an octagonal cross section, and the second tube has a square cross section.

4. The composite core, according to claim 1 , wherein the plurality of fibers of the first tube comprises:
a first set of fibers extending in a first direction; and
a second set of fibers extending in a second direction, the second set of fibers woven about the first set of fibers.

5. The composite core, according to claim 1 , wherein the plurality of fibers of the first tube comprises:
a first set of fibers extending in a first direction; and
a second set of fibers extending in a second direction, the second set of fibers overlaying the first set of fibers.

6. The composite core, according to claim 1 , wherein the plurality of fibers of the first tube comprises:
a first set of fibers of a first material; and
a second set of fibers of a second material.

7. The composite core, according to claim 1 , wherein the plurality of fibers of the first tube comprises:
a first set of fibers exhibiting a first size; and
a second set of fibers exhibiting a second size.

8. The composite core, according to claim 1 , further comprising:
an adhesive layer disposed between the first tube and the second tube.

9. The composite core, according to claim 1 , wherein the removable bands are configured to be removed during a post-operation thereby producing gaps in the weave pattern between the first tube and the second tube.

10. A composite sandwich structure, comprising:
a first skin;
a core comprising:
a first tube and a second tube, the first tube and a the second tube having a plurality of fibers woven with a plurality of removable bands and disposed in a polymeric matrix, the removable bands being configured to dissolve during a post cure operation, wherein at least some of the plurality of removable bands are woven with others of the plurality of removable bands in a weave pattern;
wherein the plurality of fibers of each of the first tube and the second tube are in contact with each other to form a cross-linked pattern, which in turn secures the first tube to the second tube via the plurality of fibers;
wherein the plurality of fibers of each tube are arranged in a uniaxial configuration so as to be arranged in a single direction, such that the plurality of fibers of each tube crosslink with fibers of adjacent tubes, the crosslinking being generated even though each tube has a plurality of fibers only in a single direction; and
wherein the first skin is adhesively bonded to a first end face of the core.

11. The composite sandwich structure, according to claim 10 , further comprising:
a second skin adhesively bonded to a second end face of the core.

Assignees

• Hethcock James D
• Nunn Kenneth E
• Oldroyd Paul
• Textron Innovations Inc

Inventors

• Hethcock James D
• Nunn Kenneth E
• Oldroyd Paul

Classifications

• B32B3/12

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

• B32B2307/50

  having particular mechanical properties · CPC title

• B32B2255/02

  on fibrous or filamentary layer · CPC title

• B32B2255/26

  Polymeric coating · CPC title

• D04C3/48

  Auxiliary devices · CPC title