Patent · US2010043955A1 · A1 · US

Flat-Cured Composite Structure

(11) Publication number

US2010043955A1

(21) Application number

US-54405509-A

(22) Filing date

2009-08-19

(30) Priority date

2008-08-21

(43) Publication date

2010-02-25

(52) CPC

B32B Layered products, i.e. products built-up of strata of flat or non-flat, e.g. cellular or honeycomb, form: 37/1018, 15/04, 2262/0269, 2262/101, 2262/105, 2305/022, 2309/04, 2309/105, 2605/18, 2607/00, 27/06, 3/12, 37/1284, 37/146, 38/1866, 5/18, 7/12
B29C Shaping or joining of plastics; shaping of material in a plastic state, not otherwise provided for; after-treatment of the shaped products, e.g. repairing: 35/02, 65/4835, 65/5021, 65/5057, 66/1122, 66/1142, 66/12441, 66/12821, 66/1284, 66/301, 66/43, 66/438, 66/45, 66/5221, 66/543, 66/547, 66/71, 66/712, 66/721, 66/7212, 66/72141, 66/723, 66/72525, 66/727, 66/7392, 66/7394, 66/742
B29K Indexing scheme associated with subclasses B29B, B29C or B29D, relating to moulding materials or to materials for {moulds, } reinforcements, fillers or preformed parts, e.g. inserts: 2077/10, 2101/10, 2101/12, 2105/04, 2105/06, 2105/24, 2277/10, 2305/00, 2305/02, 2307/00, 2309/08
B29L Indexing scheme associated with subclass B29C, relating to particular articles: 2031/3082, 2031/608
B64C Aeroplanes; helicopters: 2001/0072
Y02T Climate change mitigation technologies related to transportation: 50/40
Y10T Technical subjects covered by former us classification: 428/231, 428/24149, 428/24661, 428/249924, 428/249928, 442/3179

(73) Assignee

HORNICK DAVID C; FILA JOSEF

(54) Title

Flat-Cured Composite Structure

(57) Abstract

An embodiment of the invention includes a composite structure fabricated from at least one pre-cured flat face sheet applied to a core with an adhesive. Once the pre-cured flat face sheet is applied to the core, curing of the adhesive may take place to bond the pre-cured flat face sheet to the core. Before the bonding of the pre-cured flat face sheet to the core takes place, the pre-cured flat face sheet may be prepared by separately curing a composite face sheet.

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Claims (1)

A method for manufacturing a composite structure, the method comprising: fitting a pre-cured flat sheet to a tool; disposing an adhesive between the pre-cured flat sheet on the tool and a core to form an intermediate structure; and curing the adhesive between the cord and the pre-cured flat sheet to form a composite structure. 2. The method of claim 1, wherein disposing an adhesive between the pre-cured flat sheet on the tool and the core to form an intermediate structure comprises: disposing the adhesive on the core; and placing the core onto the pre-cured flat sheet on the tool. 3. The method of claim 1, wherein the adhesive comprises at least one of: film adhesive, heated cauls, paste adhesives, or a FM300-2 adhesive. 4. The method of claim 1, wherein the core comprises at least one of: a metallic frame, a composite frame, a honeycomb core, a metallic honeycomb core, a non-metallic honeycomb core, a foam core, or a Nomex 3 lb., 1 inch thick, ⅛ inch cell HRH 10 core. 5. The method of claim 1, wherein the pre-cured flat sheet comprises at least one of: thermoplastic resin, thermoset resin, carbon fibers, glass fibers, aramid fibers, or a M™ 45 resin, 6 plies carbon fiber (crows foot weave) sheet. 6. The method of claim 1, wherein curing the adhesive comprises at least one of the following: autoclave curing, platen press curing, or oven curing. 7. The method of claim 1, further comprising: disposing a second adhesive between a second pre-cured face sheet and a second side of the core prior to curing the adhesive and the second adhesive. 8. The method of claim 1, further comprising: placing the intermediate structure in a vacuum bag prior to curing the adhesive. 9. The method of claim 1, further comprising: bonding the composite structure to a second composite structure. 10. The method of claim 9, wherein bonding the composite structure to the second composite structure comprises forming between the composite structure and the second composite structure at least one of: an overlap splice configuration; a box longeron configuration; a H longeron configuration; an internal splice configuration; an external splice configuration; and a mixed splice configuration. 11. The method of claim 9, wherein bonding the composite structure to the second composite structure comprises forming at least one of: a window, a fuselage, a nacelle, a wing, a cowling, and a door frame. 12. The method of claim 1, further comprising: embedding a structural component into the intermediate structure in order to form a structural feature. 13. An intermediate composite structure for use in a composite structure, the intermediate composite structure comprising: a pre-cured face sheet; a core; and an uncured adhesive between the pre-cured face sheet and the core to connect the pre-cured face sheet to the core and to form an intermediate composite structure. 14. The structure of claim 13, wherein the pre-cured face sheet is fit to a tool. 15. The structure of claim 13, wherein the intermediate composite structure is placed in a vacuum bag. 16. The structure of claim 13, further comprising a second pre-cured face sheet bonded to a second side of the core with a second adhesive. 17. The structure of claim 13, wherein the adhesive comprises at least one of: film adhesive, heated cauls, paste adhesives, or a FM300-2 adhesive. 18. The structure of claim 13, wherein the core comprises at least one of: a metallic frame, a composite frame, a honeycomb core, a metallic honeycomb core, a non-metallic honeycomb core, a foam core, or a Nomex 3 lb., ⅛ inch cell HRH 10 core. 19. The structure of claim 13, wherein the pre-cured face sheet comprises at least one of: thermoplastic resin, thermoset resin, carbon fibers, glass fibers, aramid fibers, or a M™ 45 resin, 6 plies carbon fiber (crows foot weave) sheet. 20. The structure of claim 13, further comprising a structural component embedded into the intermediate composite structure. 21. A method for manufacturing a composite structure, the method comprising: fitting a first pre-cured flat sheet to a tool; applying a first adhesive between the first pre-cured flat sheet and a frame; applying a second adhesive between a second pre-cured face sheet and a second side of the frame; and curing the first adhesive and the second adhesive to form a composite structure. 22. A method for manufacturing a composite structure, the method comprising: disposing an adhesive between a pre-cured flat sheet and a core; and curing the adhesive between the core and the pre-cured flat sheet to form a composite structure. 23. A method for manufacturing a composite structure, the method comprising: performing a layup process of a plurality of fibers; curing a matrix material and the plurality of fibers to form a pre-cured sheet; disposing an adhesive between the pre-cured sheet and a core; and curing the adhesive between the core and the pre-cured sheet to form a composite stricture.

Citations (13)

JP2006007512A
JPS63293013A
US2005126699A1
US2007226981A1
US3539421A
US3866305A
US4963215A
US5455096A
US6372322B1
US6849150B1
US6852271B1
US7052734B2
US7563501B2

Record as JSON

{
  "publication_number": "US2010043955A1",
  "country": "US",
  "kind": "A1",
  "title": "Flat-Cured Composite Structure",
  "abstract": "An embodiment of the invention includes a composite structure fabricated from at least one pre-cured flat face sheet applied to a core with an adhesive. Once the pre-cured flat face sheet is applied to the core, curing of the adhesive may take place to bond the pre-cured flat face sheet to the core. Before the bonding of the pre-cured flat face sheet to the core takes place, the pre-cured flat face sheet may be prepared by separately curing a composite face sheet.",
  "claims": [
    "1. A method for manufacturing a composite structure, the method comprising: fitting a pre-cured flat sheet to a tool; disposing an adhesive between the pre-cured flat sheet on the tool and a core to form an intermediate structure; and curing the adhesive between the cord and the pre-cured flat sheet to form a composite structure. 2. The method of claim 1, wherein disposing an adhesive between the pre-cured flat sheet on the tool and the core to form an intermediate structure comprises: disposing the adhesive on the core; and placing the core onto the pre-cured flat sheet on the tool. 3. The method of claim 1, wherein the adhesive comprises at least one of: film adhesive, heated cauls, paste adhesives, or a FM300-2 adhesive. 4. The method of claim 1, wherein the core comprises at least one of: a metallic frame, a composite frame, a honeycomb core, a metallic honeycomb core, a non-metallic honeycomb core, a foam core, or a Nomex 3 lb., 1 inch thick, ⅛ inch cell HRH 10 core. 5. The method of claim 1, wherein the pre-cured flat sheet comprises at least one of: thermoplastic resin, thermoset resin, carbon fibers, glass fibers, aramid fibers, or a M™ 45 resin, 6 plies carbon fiber (crows foot weave) sheet. 6. The method of claim 1, wherein curing the adhesive comprises at least one of the following: autoclave curing, platen press curing, or oven curing. 7. The method of claim 1, further comprising: disposing a second adhesive between a second pre-cured face sheet and a second side of the core prior to curing the adhesive and the second adhesive. 8. The method of claim 1, further comprising: placing the intermediate structure in a vacuum bag prior to curing the adhesive. 9. The method of claim 1, further comprising: bonding the composite structure to a second composite structure. 10. The method of claim 9, wherein bonding the composite structure to the second composite structure comprises forming between the composite structure and the second composite structure at least one of: an overlap splice configuration; a box longeron configuration; a H longeron configuration; an internal splice configuration; an external splice configuration; and a mixed splice configuration. 11. The method of claim 9, wherein bonding the composite structure to the second composite structure comprises forming at least one of: a window, a fuselage, a nacelle, a wing, a cowling, and a door frame. 12. The method of claim 1, further comprising: embedding a structural component into the intermediate structure in order to form a structural feature. 13. An intermediate composite structure for use in a composite structure, the intermediate composite structure comprising: a pre-cured face sheet; a core; and an uncured adhesive between the pre-cured face sheet and the core to connect the pre-cured face sheet to the core and to form an intermediate composite structure. 14. The structure of claim 13, wherein the pre-cured face sheet is fit to a tool. 15. The structure of claim 13, wherein the intermediate composite structure is placed in a vacuum bag. 16. The structure of claim 13, further comprising a second pre-cured face sheet bonded to a second side of the core with a second adhesive. 17. The structure of claim 13, wherein the adhesive comprises at least one of: film adhesive, heated cauls, paste adhesives, or a FM300-2 adhesive. 18. The structure of claim 13, wherein the core comprises at least one of: a metallic frame, a composite frame, a honeycomb core, a metallic honeycomb core, a non-metallic honeycomb core, a foam core, or a Nomex 3 lb., ⅛ inch cell HRH 10 core. 19. The structure of claim 13, wherein the pre-cured face sheet comprises at least one of: thermoplastic resin, thermoset resin, carbon fibers, glass fibers, aramid fibers, or a M™ 45 resin, 6 plies carbon fiber (crows foot weave) sheet. 20. The structure of claim 13, further comprising a structural component embedded into the intermediate composite structure. 21. A method for manufacturing a composite structure, the method comprising: fitting a first pre-cured flat sheet to a tool; applying a first adhesive between the first pre-cured flat sheet and a frame; applying a second adhesive between a second pre-cured face sheet and a second side of the frame; and curing the first adhesive and the second adhesive to form a composite structure. 22. A method for manufacturing a composite structure, the method comprising: disposing an adhesive between a pre-cured flat sheet and a core; and curing the adhesive between the core and the pre-cured flat sheet to form a composite structure. 23. A method for manufacturing a composite structure, the method comprising: performing a layup process of a plurality of fibers; curing a matrix material and the plurality of fibers to form a pre-cured sheet; disposing an adhesive between the pre-cured sheet and a core; and curing the adhesive between the core and the pre-cured sheet to form a composite stricture."
  ],
  "cpc": [
    "B32B 37/1018",
    "B29C 35/02",
    "B29C 65/4835",
    "B29C 65/5021",
    "B29C 65/5057",
    "B29C 66/1122",
    "B29C 66/1142",
    "B29C 66/12441",
    "B29C 66/12821",
    "B29C 66/1284",
    "B29C 66/301",
    "B29C 66/43",
    "B29C 66/438",
    "B29C 66/45",
    "B29C 66/5221",
    "B29C 66/543",
    "B29C 66/547",
    "B29C 66/71",
    "B29C 66/712",
    "B29C 66/721",
    "B29C 66/7212",
    "B29C 66/72141",
    "B29C 66/723",
    "B29C 66/72525",
    "B29C 66/727",
    "B29C 66/7392",
    "B29C 66/7394",
    "B29C 66/742",
    "B29K 2077/10",
    "B29K 2101/10",
    "B29K 2101/12",
    "B29K 2105/04",
    "B29K 2105/06",
    "B29K 2105/24",
    "B29K 2277/10",
    "B29K 2305/00",
    "B29K 2305/02",
    "B29K 2307/00",
    "B29K 2309/08",
    "B29L 2031/3082",
    "B29L 2031/608",
    "B32B 15/04",
    "B32B 2262/0269",
    "B32B 2262/101",
    "B32B 2262/105",
    "B32B 2305/022",
    "B32B 2309/04",
    "B32B 2309/105",
    "B32B 2605/18",
    "B32B 2607/00",
    "B32B 27/06",
    "B32B 3/12",
    "B32B 37/1284",
    "B32B 37/146",
    "B32B 38/1866",
    "B32B 5/18",
    "B32B 7/12",
    "B64C 2001/0072",
    "Y02T 50/40",
    "Y10T 428/231",
    "Y10T 428/24149",
    "Y10T 428/24661",
    "Y10T 428/249924",
    "Y10T 428/249928",
    "Y10T 442/3179"
  ],
  "assignees": [
    "HORNICK DAVID C",
    "FILA JOSEF"
  ],
  "filing_date": "2009-08-19",
  "publication_date": "2010-02-25",
  "priority_date": "2008-08-21",
  "application_number": "US-54405509-A",
  "family_id": "41695226",
  "citations": [
    "JP2006007512A",
    "JPS63293013A",
    "US2005126699A1",
    "US2007226981A1",
    "US3539421A",
    "US3866305A",
    "US4963215A",
    "US5455096A",
    "US6372322B1",
    "US6849150B1",
    "US6852271B1",
    "US7052734B2",
    "US7563501B2"
  ]
}

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