IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0705675
(2010-02-15)
|
등록번호 |
US-8431214
(2013-04-30)
|
발명자
/ 주소 |
|
출원인 / 주소 |
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
3 인용 특허 :
49 |
초록
▼
A polymer-based composite sandwich includes a reinforced core bonded between a pair of composite facesheets. The core includes a truss formed by groups of composite pins held in place by a layer of structural foam. The pins in the groups are radially arranged around nodes. The ends of the pins are s
A polymer-based composite sandwich includes a reinforced core bonded between a pair of composite facesheets. The core includes a truss formed by groups of composite pins held in place by a layer of structural foam. The pins in the groups are radially arranged around nodes. The ends of the pins are splayed and sandwiched between the foam layer and the facesheets.
대표청구항
▼
1. A composite sandwich, comprising: a first composite facesheet and a second composite facesheet; anda reinforced core sandwiched between the first composite facesheet and second composite facesheet, the reinforced core including: a plurality of pins arranged in groups forming a truss, wherein the
1. A composite sandwich, comprising: a first composite facesheet and a second composite facesheet; anda reinforced core sandwiched between the first composite facesheet and second composite facesheet, the reinforced core including: a plurality of pins arranged in groups forming a truss, wherein the plurality of pins include medial portions extending between the first composite facesheet and the second composite facesheet and distal portions respectively extending generally parallel with and bonded to the first composite facesheet and the second composite facesheet, wherein the plurality of pins further comprise first ends and second ends, and wherein the groups comprise subsets of three or more pins of the plurality of pins that are arranged in a crossing pattern at about the corresponding first ends, are spaced apart at about the corresponding first ends, are substantially circumferentially spaced equally from each other at about the first ends, and wherein each pin of the three or more pins overlaps at least one first other pin of the three or more pins and is overlapped by at least one second other pin of the three or more pins; anda carrier surrounding the pins. 2. The composite sandwich of claim 1, wherein corresponding locations where the corresponding first ends of the subsets of pins are touching comprise corresponding nodes. 3. The composite sandwich of claim 2, wherein distal portions of the pins in each of the groups radiate outwardly from the corresponding nodes. 4. The composite sandwich of claim 2, wherein the corresponding nodes of the groups are spaced substantially equidistant from each other. 5. The composite sandwich of claim 1, wherein the distal portions of each of the pins are splayed and are sandwiched between the core and one of the first composite facesheet and the second composite facesheet. 6. The composite sandwich of claim 1, wherein: each of the pins includes carbon fiber reinforced resin, andeach of the first composite facesheet and the second composite facesheet includes laminated plies of carbon fiber reinforced resin. 7. The composite sandwich of claim 1, wherein pins in each of the groups are inclined relative to planes of the facesheets. 8. The composite sandwich of claim 1, wherein the carrier includes rigid foam. 9. The composite sandwich of claim 1, wherein the carrier is closed cell foam, and the core has a density of between approximately 6.9 and 12 pounds per cubic foot. 10. The composite sandwich of claim 1, wherein the composite sandwich is part of an aircraft structure. 11. A reinforced composite sandwich core formable into a curved shape, comprising: a first plurality of pins comprising at least a first pin having a first end, a second pin comprising a second end, and a third pin comprising a third end, wherein the first end, the second end, and the third end are spaced apart and arranged in a first crossing pattern at the first node; are spaced apart at about the first end, second end, and third end; are substantially circumferentially spaced equally from each other at about the first end, second end, and third end; and wherein each pin of the first pin, the second pin, and the third pin overlaps at least one first other pin of the first pin, the second pin, and the third pin and is overlapped by at least one second other pin of the first pin, the second pin, and the third pin;a second plurality of pins comprising at least a fourth pin having a fourth end, a fifth pin having a fifth end, and a sixth pin having a sixth end, wherein the fourth end, the fifth end, and the sixth end are spaced part and arranged in a second crossing pattern at the second node, and wherein the first plurality of pins and the second plurality of pins are arranged into a truss structure; are spaced apart at about the fourth end, fifth end, and sixth end; are substantially circumferentially spaced equally from each other at about the fourth end, fifth end, and sixth end;and wherein each pin of the fourth pin, the fifth pin, and the sixth pin overlaps at least one third other pin of the fourth pin, the fifth pin, and the sixth pin and is overlapped by at least one fourth other pin of the fourth pin, the fifth pin, and the sixth pin; anda flexible carrier for supporting the first plurality of pins and the second plurality of pins, wherein pins in the first plurality of pins and the second plurality of pins are spaced apart from and displaceable relative to each other within the carrier upon forming of the carrier into the curved shape. 12. The reinforced composite sandwich core of claim 11, wherein the first plurality of pins is radially distributed around the first node and wherein the second plurality of pins is radially distributed around the second node. 13. The reinforced composite sandwich core of claim 11, wherein: the carrier includes a layer of uncured thermoset foam, and the pins are a thermoset prepreg. 14. The reinforced composite sandwich core of claim 11, wherein: the carrier includes a foam layer, wherein the pins include medial portions held within the foam layer, and wherein distal portions of the pins extend outside of the foam layer. 15. The reinforced composite sandwich core of claim 14, wherein the distal portions are splayed and lie substantially flush along a face of the foam layer. 16. A method of fabricating a reinforced composite sandwich, comprising: fabricating a core having a first surface and a second surface opposite the first surface, wherein fabricating includes: inserting into a closed cell carrier foam a plurality of pins in groups to form a truss, wherein the plurality of pins further comprise first ends and second ends, and wherein the groups comprise subsets of three or more pins of the plurality of pins that are spaced apart and arranged in a crossing pattern at about the corresponding first ends, are substantially circumferentially spaced equally from each other at about the first ends, and wherein each pin of the three or more pins overlaps at least one first other pin of the three or more pins and is overlapped by at least one second other pin of the three or more pins; andsealing porosity in the closed cell carrier foam created by insertion of the plurality of pins by applying a first plurality of layers of solid film adhesive on the first surface and a second plurality of layers of solid film adhesive on the second surface;forming the core into a curved shape;applying a first facesheet to the first surface and a second facesheet to the second surface such that the plurality of pins include medial portions extending between the first facesheet and the second facesheet and distal portions respectively extending generally parallel with and bonded to the first facesheet; andcuring the core, the first facesheet, and the second facesheet. 17. The method of claim 16, wherein arranging the plurality of pins includes inserting the plurality of pins into the closed cell carrier foam at differing angles. 18. The method of claim 16, wherein fabricating the core further comprises bending the first ends of the plurality of pins onto the first plurality of layers and the second ends of the plurality of pins onto the second plurality of layers. 19. The method of claim 18, wherein fabricating the core further comprises flaying the first ends and the second ends. 20. The method of claim 19, wherein fabricating the core further comprises sandwiching flayed ends of the plurality of pins between the first facesheet and the first plurality of layers, and between the second facesheet and the second plurality of layers, respectively. 21. The method of claim 16, wherein forming the core into a curved shape includes: bending the closed cell carrier foam, and displacing the plurality of pins in each group relative to each other as the closed cell carrier foam is being bent.
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