Process or system to reduce cost and weight of aerospace interior structural thermoplastic or composite panel constructions

Patent metadata

Field	Value
Publication number	US-9862164-B2
Application number	US-201514708713-A
Country	US
Kind code	B2
Filing date	May 11, 2015
Priority date	May 11, 2015
Publication date	Jan 9, 2018
Grant date	Jan 9, 2018

Abstract

Methods for manufacturing composite panels for use in the interior of an aircraft are disclosed, specifically, methods of manufacturing joggled composite panels comprising metal inserts and the resulting composite panels and inserts.

First claim

What is claimed:

1. A method for manufacturing a composite panel, the method comprising:
providing a first layer on a tool, wherein the tool is adapted to receive a plurality of pins;
inserting the plurality of pins into the tool;
positioning a plurality of inserts on the first layer, wherein the plurality of inserts are adapted to connect to the plurality of pins;
connecting the plurality of inserts to the pins;
positioning a plurality of core portions adjacent to the plurality of inserts;
providing a second layer on the plurality of core portions in order to form a non-cured composite panel;
positioning a plate on the non-cured composite panel; and
curing the non-cured composite panel in order to form a composite panel.

2. The method of claim 1 , wherein the plurality of inserts comprise a metal.

3. The method of claim 2 , wherein the plurality of inserts comprise aluminum.

4. The method of claim 1 , wherein the plurality of inserts comprises a first insert and a second insert.

5. The method of claim 4 , wherein the plurality of pins comprises a first pin, a second pin, a third pin, and a fourth pin.

6. The method of claim 5 , further comprising connecting the first insert to the tool with the first pin and the second pin and connecting the second insert to the tool with the third pin and the fourth pin.

7. The method of claim 6 , wherein the plurality of core portions comprises a first core portion, a second core portion, and a third core portion.

8. The method of claim 7 , further comprising positioning the first core portion adjacent to the first insert; positioning the second core portion in between the first insert and the second insert; and positioning the third core portion adjacent to the second insert.

9. The method of claim 1 , wherein the plurality of core portions bond to the plurality of inserts during curing.

10. The method of claim 8 , wherein the composite panel is a joggled composite panel.

11. The method of claim 10 , wherein the first insert, the second core portion, and the second insert form a joggled portion of the joggled composite panel.

12. A composite panel manufactured according to the method of claim 1 .

13. The composite panel of claim 12 , wherein the plurality of inserts comprise a metal.

14. The composite panel of claim 13 , wherein the plurality of inserts comprise aluminum.

15. The composite panel of claim 12 , wherein the plurality of inserts comprise a first insert and a second insert.

16. The composite panel of claim 15 , wherein the plurality of core portions comprise a first core portion, a second core portion, and a third core portion.

17. The composite panel of claim 16 , wherein the first insert, the second core portion, and the second insert form a joggled portion.

18. The composite panel of claim 12 , wherein the plurality of core portions comprise honeycomb core material.

19. The composite panel of claim 12 , wherein the first layer and the second layer comprise laminate material.

20. An insert for use in the composite panel of claim 12 , the insert comprising a top portion, a bottom portion, a first side portion, a second side portion, a middle portion, and a plurality of insert pin holes,
wherein the top portion is longer than the bottom portion, and
wherein the middle portion is arranged between the first side portion and the second side portion in order to form two openings.

Assignees

• Boeing Co

Inventors

• Gray Kyle L
• Cuddy Nathanial C
• Erickson Harold G

Classifications

• B29C70/00

  Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts · CPC title

• B32B3/18 Primary

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

• B32B27/42

  comprising condensation resins of aldehydes, e.g. with phenols, ureas or melamines · CPC title

• B32B1/00

  Layered products having a non-planar shape · CPC title

• B32B27/06

  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 layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08)} · CPC title