COMPOSITE CORE STRUCTURES FOR AIRCRAFT
20230382510 · 2023-11-30
Inventors
Cpc classification
B32B37/146
PERFORMING OPERATIONS; TRANSPORTING
B64F5/00
PERFORMING OPERATIONS; TRANSPORTING
B32B27/12
PERFORMING OPERATIONS; TRANSPORTING
B32B2307/7375
PERFORMING OPERATIONS; TRANSPORTING
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
B32B2260/021
PERFORMING OPERATIONS; TRANSPORTING
B64C1/00
PERFORMING OPERATIONS; TRANSPORTING
B32B2250/40
PERFORMING OPERATIONS; TRANSPORTING
B32B37/185
PERFORMING OPERATIONS; TRANSPORTING
B32B3/06
PERFORMING OPERATIONS; TRANSPORTING
International classification
B64C1/00
PERFORMING OPERATIONS; TRANSPORTING
B64F5/00
PERFORMING OPERATIONS; TRANSPORTING
B32B3/12
PERFORMING OPERATIONS; TRANSPORTING
B32B3/06
PERFORMING OPERATIONS; TRANSPORTING
B32B37/14
PERFORMING OPERATIONS; TRANSPORTING
B32B37/18
PERFORMING OPERATIONS; TRANSPORTING
B32B5/02
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A core structure (300) for a composite panel for an aircraft, for example a door fairing for a landing gear bay, including a sandwich structure in which core cells (301) are sandwiched between first and second body sides (skins 303, 305). The core cells are square or rectangular in shape and each have a void formed by cell walls (307). The first and second body sides and the cell walls include laminated composite material of multiple layers. Drainage holes (320) in the cell walls form one or more direct drainage paths (P2, P3) for the flow of fluid from the core structure. The core cells include first and second sheets of cells reversibly mounted to each other, such that the void of each cell is formed in part by the first sheet and in part by the second sheet.
Claims
1. A core structure for a composite panel for an aircraft, the core structure comprising: a first body side, a second body side, and a plurality of core cells extending between the first body side and the second body side, wherein each cell of the plurality of core cells comprises: at least one cell wall, extending parallel to a cell axis that is perpendicular to the first body side and second body side, a void surrounded by the at least one cell wall, and at least one drainage hole in the at least one cell wall, wherein the drainage holes in the cell walls form a direct drainage path for the flow of fluid from the core structure, the direct drainage path passing through the plurality of core cells and across the core structure in a direction parallel to at least one of the first body side and the second body side.
2. The core structure of claim 1, wherein the plurality of core cells of the core structure are arranged to be aligned such that the drainage path formed by the plurality of core cells is linear.
3. The core structure of claim 1, wherein the drainage path has a path length from a start of the drainage path to an end of the drainage path, wherein the path length is substantially the same as a shortest distance, as measured parallel to at least one of the first body side and the second body side, from the start of the drainage path to the end of the drainage path.
4. The core structure of claim 1, wherein the core structure has a length and a width, and wherein the drainage path is aligned with the length or the width of the core structure.
5. The core structure of claim 1, wherein the at least one cell wall includes four cell walls, said four cell walls arranged to form a prism having a quadrilateral base.
6. The core structure of claim 1, wherein at least one of the cell walls of each of the plurality of core cells has a length greater than 40 mm.
7. The core structure of claim 1, wherein at least one of the cell walls of each of the plurality of core cells has a thickness greater than 3 mm.
8. The core structure of claim 1, wherein each of the cell walls comprises a laminated composite material, each of the cell walls has a height parallel to the cell axis, a length and a wall thickness, and the laminated composite material comprises a plurality of layers stacked across the wall thickness.
9. The core structure of claim 8, wherein the laminated composite material comprises at least 5 layers at a thickest region of the laminated composite material.
10. The core structure of claim 1, wherein the first body side and the second body side each have a thickness and each comprise a laminated composite material, and wherein the laminated composite material comprises a plurality of layers stacked across the thickness.
11. The core structure of claim 1, wherein the height of the core structure along the cell axis is in a range of 50 mm to 250 mm.
12. The core structure of claim 1, wherein the plurality of core cells comprise a material formed of aromatic polyamide-aramid-fibres and epoxy resin.
13. The core structure of claim 1, wherein the plurality of core cells comprises a first sheet of cells and a second sheet of cells, the first sheet of cells being reversibly mounted to the second sheet of cells such that the void of each of the cells is formed in part by the first sheet and in part by the second sheet.
14. The core structure of claim 13, wherein the first sheet of cells and the second sheet of cells comprise a male-female connector configured to enable the sheets to be reversibly mounted to each-other.
15. The core structure of claim 14, wherein the male-female connector is configured such that the first sheet is reversibly mounted to the second sheet via a push fit configuration.
16. A method of forming the core structure of claim 1, the method comprising bonding the first body side and the second body side together such that the plurality of core cells are fixed between the first body side and the second body side.
17. A method of forming the core structure of claim 1, comprising: positioning a mould on a first body side to form a lay-up surface, positioning layers of uncured material on said lay-up surface such that at least part of the uncured material interfaces with the first body side, curing the material positioned on the lay-up surface in order to form the plurality of core cells and to bond them to the first body side, and bonding a second body side to the plurality of core cells.
18. A method of forming a core structure comprising: positioning layers of uncured material on a first lay-up surface such that at least part of the uncured material interfaces with a first body side to form a first sheet of cells, positioning layers of uncured material on a second lay-up surface such that at least part of the uncured material interfaces with a second body side to form a second sheet of cells, and co-bonding the first and second sheets of cells together to form the core structure.
19. The method of claim 18 wherein the first body side and/or the second body side are provided as a plurality of plies of an uncured composite, and the method further comprises bending some of the plies of the first body side and/or second body side to place the uncured material into the shape of the first sheet of cells and/or second sheet of cells.
20. The method of claim 18, wherein the method comprises the steps of curing the first sheet of cells and/or the second sheet of cells prior to the step of co-bonding the first and second sheets of cells together to form the core structure.
21. A method of forming the core structure of claim 13, the method comprising: positioning a mould on a first body side to form a first lay-up surface, positioning layers of uncured material on said first lay-up surface such that at least part of the uncured material interfaces with the first body side, curing the material positioned on the first lay-up surface to form a first sheet of cells and to bond them to the first body side, positioning a mould on a second body side to form a second lay-up surface, positioning layers of uncured material on said second lay-up surface such that at least part of the uncured material interfaces with the second body side, curing the material positioned on the second lay-up surface to form a second sheet of cells and to bond them to the second body side, and joining the first and second sheet of cells together to form the core structure.
22. The method of claim 18, wherein the step of joining the first and second sheet of cells together comprises joining the first and second sheets by pushing a male part of one of the first and second sheets into a female part of the other of the first and second sheets, for example as a push-fit.
23. The method of claim 17, wherein the uncured material is co-cured with the first body side and second body side during the curing step.
24. A method of designing the core structure of claim 1, wherein the method comprises selecting a cell size and cell wall properties to produce a core structure having a desired bending stiffness about at least one axis and a desired torsional stiffness about at least one axis.
25. The method of claim 24, wherein the selecting of the cell wall properties includes selecting a number of layers of material for forming a laminated composite material cell wall.
26. A structural panel for an aircraft comprising the core structure of claim 1.
27. A structural panel for the aircraft of claim 26, wherein the structural panel is a landing gear bay door for attachment to a main landing gear of an aircraft.
28. A sub-assembly of an aircraft comprising the structural panel of claim 26.
29. An aircraft comprising the structural panel of claim 26.
Description
DESCRIPTION OF THE DRAWINGS
[0074] Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which:
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DETAILED DESCRIPTION
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[0090] The cell walls 207 are shown in
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[0093] Co-curing of the core structure 300 in two halves in this way has a number of advantages. It allows the cells 301 to be cured strongly to the first skin 303 and second skin 305 without the need for additional adhesive layers. Moreover, when cured in this way, initially the voids 309 are open. This makes it easier to remove any lay-up structures (not shown) used in forming the core cells. In addition, it allows for any excess resin to be drained quickly before/during curing, especially if a wet lay-up method is used. The first co-curing can be performed using out of autoclave technology. The first half and second half are then joined in order to form the completed core structure. This is shown in more detail in
[0094] The structure comprises a plurality of drain holes 320. The drain holes 320 are aligned at the corners of each cell 301 such that straight drainage paths P2, P3 are formed that are orthogonal to each other. Drainage paths P2, P3 have the same length as the width and length of the panel respectively. Drainage paths P2, P3 are arranged to run in a direction parallel to the plane of both the first skin 303 and second skin 305, and allows fluid to flow along drainage paths P2, P3 in directions that are perpendicular to the cell axis A2. Drainage paths P2, P3 are slightly displaced to each corner of the plurality of cells 301.
[0095] As a result, P2 and P3 are straight drainage paths that give moisture that has entered into the core structure 320 a relatively short and direct route to the edge of core structure 320, where it can leave the core structure 300. This allows for a less tortuous drainage path than those that are provided by hexagonal cell arrangements, such as those shown in
[0096] In addition the cells being large allow the panel to have much lower torsional to bending stiffness ratios relative to a hex honeycomb core. This makes the core structure 300 particularly suited for mechanised door or bay openings or the like, as the increased torsional malleability allows the core structure 300 to be mechanically warped slightly around openings, ensure the closure of said openings. Maintaining the high bending stiffness ensures that the core structure 300 does not fail when subjected to high force situations, e.g. when exposed to strong airflow. It also allows the core structure 300 to have a high strength to weight ratio. Such a core structure 300 has a lower torsion stiffness to bending stiffness ratio. The core structure when used as part of a main landing gear door is described in
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[0099] After the bending/peeling has taken place, the first half 415 and second half 417 are cured. Then, the male connector 419 and female connector 421 are placed in contact with each other and the halves (415, 417) are co-cured (in a second curing cycle) to form the complete core structure 400.
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[0104] Providing 3000 a first and second skin as uncured layers of pre-impregnated material;
[0105] Positioning 3100 a mould on the first skin in order to form a lay-up surface. The lay-up surface supports the uncured layers of pre-preg material, and also provides an area on which further uncured layers can be placed in an orientation that is substantially perpendicular to the first skin.
[0106] Placing 3200 uncured layers of pre-impregnated material on the mould to interface with the first skin;
[0107] Co-curing 3300 the first skin and the uncured layers of material to form a plurality of cells on the first skin, the plurality of cells having voids, and being open at an end of the cell distal to the end of the cell bonded to the first skin, the step of forming a plurality of cells on the first skin includes the step of bending (or otherwise ‘peeling’) the first skin in order to form layers of material that extend substantially perpendicularly away from the first skin. It will be understood that any moulds are removed prior to the co-curing 3300;
[0108] Repeating 3400 the steps above for a second skin in order to form cells on the second skin.
[0109] Joining 3500 the first and second skins at the open ends of their cells in order to form a closed cell structure between the first and second skins. In this embodiment the joining is performed by co-bonding the first and second skins.
[0110] The plurality of cells on the first and/or second skin are cured prior to the step of joining 3500 the first and second skins at the open ends of their cells in order to form a closed cell structure. This helps form a male connector on the plurality of cells of the first skin and a female connector on the plurality of cells of the second skin. The male connector and female connector are then interfaced prior to the co-bonding of the first and second skins to form a closed cell structure.
[0111] The bending of the layers occurs prior to curing (or co-curing) of the first and/or second skin. The layers are bent upwards and supported by a mould before any curing or co-curing takes place. In some embodiments of the invention, the bending may include cutting and or stitching the layers of material to form laminate material in the shape of the plurality of cells.
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[0115] If the walls of the plurality of core cells are themselves made of laminate material, selecting 4150 a number of laminate layers.
[0116] Manufacturing 4200 a core structure with said size and shape (and number of layers).
[0117] The layers of material that form the walls of the cells of the structure may be laid up in alternating layers of fibre orientation, e.g. +45 degrees followed by −45 degrees.
[0118] Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated. By way of example only, certain possible variations will now be described.
[0119] The resin used in the composites described in the first and second embodiments is epoxy resin. However, the skilled person would appreciate that other thermoset or thermoplastic polymers, such as polyester, vinyl ester, or nylon may be used instead, if appropriate to do so.
[0120] In the first and second embodiments, the core material used is a laminated composite material such as glass fibre reinforced composites and carbon fibre reinforced composites. Other alternative reinforced composites could be used and include basalt based fibre composites for example. Aramid fibre based composites, such as Nomex® may be equally employed in embodiments of the invention, whether a square, hexagonal, or other configuration are employed. Such embodiments could for example equally benefit from mechanical properties which maintain bending stiffness and reduce torsional stiffness. Applying the configuration and/or engineering principles of the above embodiments to a Nomex® core may also allow for improved drainage properties.
[0121] In addition, in yet further embodiments of the invention, the first and second skin of the core structure may be formed of metal, such as aluminium foil, and or laminates of titanium alloy, for example. The first and second skin may also include hard wearing surface layers, which include paint or enamelling, for example—these hard wearing layers would be conventional in nature and known to the skilled person. The plurality of core cells may also comprise metal or metal composites.
[0122] The panels of the second and third embodiments, the cells are described as having cell sizes of 42 mm and 58 mm respectively. However it is appreciated that the improved mechanical properties of some embodiments of the invention can be achieved with a cell size as low as 10 mm. Larger cells sizes may provide advantages in other applications, with some embodiments having cell sizes up to, say, 500 mm. The wall thickness in applications with larger cells sizes may be as thick as, say, 50 mm.
[0123] While the drainage paths described in accordance with the third embodiment are orthogonal to each other, it is within the scope of the invention for other arrangements of substantially straight drainage paths to be incorporated into the structure. For example, the plurality of cells may be made up of a number of tessellating triangular prisms, which form a plurality of straight drainage paths that are at non-orthogonal orientations to each other. It should also be understood that a “straight” drainage path (e.g. such as the drainage path described and shown in the second embodiment) refers to a drainage path which does not take a meandering or tortuous path (such as the drainage path described and shown in the first embodiment, which is not considered to be straight or linear), and does not mean a mathematically perfectly straight path; the skilled person would understand this to include paths which have relatively minor levels of curvature and/or deviation from a mathematically straight path. The drainage holes may relative large, and may scale with the cell size. Drainage holes having a hole-size of significantly greater than 10 mm may be possible in certain embodiments.
[0124] Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.
[0125] The term ‘or’ shall be interpreted as ‘and/or’ unless the context requires otherwise.