OPTIMIZED RIB-STIFFENED COMPOSITE STRUCTURE

Abstract

A rib-stiffened composite structure includes a composite face sheet having a continuous reinforcing fiber in a polymer matrix. A polymer core is in a grid pattern disposed on the composite face sheet, the grid pattern having a first series of paths crossing over a second series of paths. Material voids are formed in the spaces between the series of paths. A composite rib-cap is disposed upon an upper surface of the polymer core. The composite rib-cap includes a continuous reinforcing fiber in a polymer matrix. The fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of paths of the grid pattern of the extruded polymer core.

Claims

1. A method for manufacturing a rib-stiffened composite structure, the method comprising the steps of: forming a composite face sheet having a continuous reinforcing fiber in a polymer matrix; forming a composite rib cap having a continuous reinforcing fiber in a polymer matrix, wherein the composite rib cap is formed in a grid pattern, the grid pattern comprising a first series of paths crossing over a second series of paths wherein material voids are formed in the spaces between the series of paths; wherein fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of paths; providing a first mold securing the composite rib cap a distance from the composite face sheet, the first mold extending through the material voids of the composite rib cap and engaging with the composite face sheet forming a hollow space between the composite face sheet and composite rib cap; injecting a core material into the hollow space delimited by the composite face sheet, the composite rib cap and the first mold; and removing the first mold from the composite face sheet, composite rib cap and core material thereby resulting in the rib-stiffened composite structure.

2. The method of claim 1, wherein a side wall of the core material is not covered by either the composite face sheet or the composite rib cap.

3. The method of claim 1, wherein the polymer used in the polymer matrix of the face sheet and rib cap is the same polymer used in the core material.

4. The method of claim 1, wherein the injection of the core material into the hollow space delimited by the composite face sheet, the composite rib cap and the first mold comprises injection molding, compression molding, transfer molding or resin transfer molding.

5. A method for manufacturing a rib-stiffened composite structure, the method comprising the steps of: forming a composite face sheet having a continuous reinforcing fiber in a polymer matrix; depositing an extruded polymer core in a grid pattern on the composite face sheet, the grid pattern comprising a first series of paths crossing over a second series of paths wherein material voids are formed in the spaces between the series of paths, wherein the extruded polymer core is deposited using a plurality of layers by a material extrusion process; and depositing a composite rib-cap upon an upper surface of the extruded polymer core, the composite rib-cap comprising a continuous reinforcing fiber in a polymer matrix, wherein fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of paths of the grid pattern of the extruded polymer core.

6. The method of claim 5, wherein a side wall of the core material is not covered by either the composite face sheet or the composite rib cap.

7. The method of claim 5, wherein the polymer used in the polymer matrix of the face sheet and rib cap is the same polymer used in the extruded polymer core.

8. The method of claim 5, wherein the first series of paths crossing over the second series of paths define junctions, where each junction has alternating continuous prepreg layers of the first series and second series of paths forming a junction of similar thickness to the rest of the first and second series of paths.

9. A rib-stiffened composite structure, comprising: a composite face sheet having a continuous reinforcing fiber in a polymer matrix; a polymer core in a grid pattern disposed on the composite face sheet, the grid pattern comprising a first series of paths crossing over a second series of paths wherein material voids are formed in the spaces between the series of paths; and a composite rib-cap disposed upon an upper surface of the polymer core, the composite rib-cap comprising a continuous reinforcing fiber in a polymer matrix, wherein fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of paths of the grid pattern of the extruded polymer core.

10. The rib-stiffened composite structure of claim 9, wherein the polymer used in the polymer matrix of the face sheet and rib cap is the same polymer used in the polymer core.

11. The rib-stiffened composite structure of claim 9, wherein a side wall of the core material is not covered by either the composite face sheet or the composite rib cap.

12. The rib-stiffened composite structure of claim 9, wherein the core material is a polymer foam, a syntactic foam, a closed cell foam, an unfilled polymer, or a filled polymer where a filler is a chopped fiber, a nanotube or graphene.

13. The rib-stiffened composite structure of claim 9, wherein the continuous reinforcing fiber of the composite face sheet and/or composite rib cap comprises carbon fiber and/or glass fiber.

14. The rib-stiffened composite structure of claim 9, wherein the composite face sheet is planar and/or the composite rib cap is planar.

15. The rib-stiffened composite structure of claim 9, wherein the composite face sheet comprises at least one curve.

16. The rib-stiffened composite structure of claim 15, wherein the composite rib cap comprises a similar curve to the at least one curve of the composite face sheet.

17. The rib-stiffened composite structure of claim 9, where the rib-stiffened composite structure is made by a method comprising the following steps: forming the composite face sheet; forming the composite rib cap; wherein fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of paths; providing a first mold securing the composite rib cap a distance from the composite face sheet, the first mold extending through the material voids of the composite rib cap and engaging with the composite face sheet forming a hollow space between the composite face sheet and composite rib cap; injecting a core material into the hollow space delimited by the composite face sheet, the composite rib cap and the first mold; and removing the first mold from the composite face sheet, composite rib cap and core material thereby resulting in the rib-stiffened composite structure.

18. The rib-stiffened composite structure of claim 17, wherein the injection of the core material into the hollow space delimited by the composite face sheet, the composite rib cap and the first mold comprises injection molding, compression molding, transfer molding or resin transfer molding.

19. The rib-stiffened composite structure of claim 9, where the rib-stiffened composite structure is made by a method comprising the following steps: forming the composite face sheet; depositing the extruded polymer core in the grid pattern on the composite face sheet, wherein the extruded polymer core is deposited using a plurality of layers by a material extrusion process; and depositing the composite rib-cap upon an upper surface of the extruded polymer core, wherein fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of paths of the grid pattern of the extruded polymer core.

20. The rib-stiffened composite structure of claim 19, wherein the first series of paths crossing over the second series of paths define junctions, where each junction has alternating continuous prepreg layers of the first series and second series of paths forming a junction of similar thickness to the rest of the first and second series of paths.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] The accompanying drawings illustrate the invention. In such drawings:

[0033] FIG. 1 is a sectional side view showing a first embodiment of a method of manufacturing a rib-stiffened composite structure having a composite face sheet and a composite rib cap;

[0034] FIG. 2 is a continuation from FIG. 1 now showing a mold disposed over the face sheet and rib cap thus forming a molding chamber for the receival of an injection molded core;

[0035] FIG. 3 is a continuation from FIG. 1 now showing the molded core between the face sheet and rib cap;

[0036] FIG. 4 is a continuation from FIG. 3 now showing the molds removed and revealing the completed structure of the rib-stiffened composite structure of FIGS. 1-3;

[0037] FIG. 5 is an isometric view of the structure of FIG. 4 illustrating an orthogrid type structure;

[0038] FIG. 6 is a sectional side view showing a second embodiment of a method of manufacturing a rib-stiffened composite structure starting with a composite face sheet;

[0039] FIG. 7 is a continuation from FIG. 1 now showing a core material being dispensed in layers directly onto the face sheet thus forming the rib structure;

[0040] FIG. 8 is a continuation from FIG. 7 now showing a prepreg material being disposed directly onto the ribs to form the rib cap;

[0041] FIG. 9 is a continuation from FIG. 8 now revealing the completed structure of the rib-stiffened composite structure of FIGS. 6-8;

[0042] FIG. 10 is an isometric view of the structure of FIG. 9 illustrating an orthogrid type structure;

[0043] FIG. 11A is an isometric view of a rib cap being laid down in a first step with a segmented prepreg path;

[0044] FIG. 11B is a continuation from FIG. 11A now showing a second step with a continuous prepreg path in a perpendicular direction;

[0045] FIG. 11C is a continuation from FIG. 11B now showing a third step with a continuous prepreg path in another perpendicular direction; and

[0046] FIG. 11D is a continuation from FIG. 11C now showing a fourth step with a segmented prepreg path in another perpendicular direction resulting in a uniform path thickness throughout the grid pattern.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0047] FIG. 1 is a sectional side view of one embodiment of a method for manufacturing a rib-stiffened composite structure 10. FIG. 1 shows a composite face sheet 12 having a continuous reinforcing fiber in a polymer matrix. A distance away 13 and above the face sheet is positioned a composite rib cap 14 also having a continuous reinforcing fiber in a polymer matrix. As shown here and for any embodiments discussed herein, the continuous reinforcing fiber of the composite face sheet and/or composite rib cap may comprise carbon fiber and/or glass fiber.

[0048] It is noted that the composite rib cap is formed in a grid pattern as may best be understood when looking at FIG. 5 which shows the completed rib-stiffened structure 10. Here, the grid pattern is a simplistic orthogrid, but it understood by those skilled in the art that any grid configuration could be used, including but not limited to, any number of parallel or non-parallel ribs running across any other number of parallel or non-parallel ribs. Here, as shown in FIG. 5, the grid pattern comprises a first series of parallel lines 16 crossing over a second series of parallel lines 18 wherein material voids 20 are formed in the spaces between the series of parallel lines. The lines have width, such that they may be also described as paths or sections. Also, as mentioned above, the lines may not be parallel to one another but at varying angles depending upon the structural needs of the overall assembly. Furthermore, the lines/paths may be curved and not following along a straight line.

[0049] The fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of parallel lines. This means for ribs 16 the fibers are running along direction 17 and for ribs 18 the fibers are running along direction 19.

[0050] FIG. 2 is similar to FIG. 1 but now shows a first mold 22 being positioned over the composite rib cap 14. As shown here, the composite face sheet 12 and rib cap 14 are disposed horizontally. However, it is noted that in actual use, it is likely they would be positioned vertically such that the first mold 22 could more easily capture the rib cap therein within. Accordingly, the use of the horizontally depicted images is for ease of understanding the differences between each step.

[0051] As shown in FIG. 2, the first mold secures the composite rib cap the distance 13 from the composite face sheet. The first mold extends through at portion 23 in the material voids of the composite rib cap and engages with the composite face sheet thereby forming a hollow space 24 between the composite face sheet and composite rib cap. Optionally, a second mold 26 can be placed on a backside 27 of the composite face sheet to provide additional structural support. (The backside 27 is opposite a frontside 28 of the face sheet 12 as best shown in FIG. 1.) The molds 22 and 26 can be made from steel, stainless steel, aluminum or any metal suitable for an injection molding process. Alternatively, even other composite structures or materials may be used to form the molds.

[0052] FIG. 3 shows injection molding a core material 30 into the hollow space 24 delimited by the frontside of the composite face sheet, the composite rib cap and the first mold. In the case of thermoplastic core materials the core material 30 would be hot and pressurized as it was being injected, but would then cool and bond to the composite face sheet and rib cap. In the case of thermoset core materials the resin would be cured, generally requiring heating, to bond to the face sheet and rib cap.

[0053] After cooling, the first mold and second molds are removed from the composite face sheet, composite rib cap and core material thereby resulting in the rib-stiffened composite structure as shown in FIG. 4.

[0054] As can be seen in FIGS. 4 and 5, the various side walls 32 of the core material are not covered by either the composite face sheet or the composite rib cap. This is important because it prevents the absorption of moisture between an encapsulated core, which can lead to delamination and failure of the structure.

[0055] It is also noted that the side walls of the core material and the sides 32 of the rib caps may be made a draft angle (0 degrees up to 45 degrees) to help in mold release. Typically, angles of 1 to 5 degrees are used. Additionally, the sidewalls of the molds themselves may be coated with a mold release compound which prevents the core material from bonding to the mold.

[0056] As shown here and for any embodiments discussed herein, the core material may be a polymer foam or a syntactic foam. Additionally, the core material may be a closed cell foam, an unfilled polymer, or a filled polymer where a filler can be but is not limited to a chopped fiber, a nanotube or graphene.

[0057] As can be seen from FIGS. 4 and 5, the composite face sheet, the composite rib cap and resulting rib-stiffened composite structure is planar. However, it is understood by those skilled in the art that these structures can be made to have one curve, two curves or any number of compound curves and features, such that the curves of the face sheet and rib caps match one another or don't match one another with varying heights of the material foam core. It is also understood by those skilled in the art that special tooling may be required for complex shapes so that the tooling can be removed. Such special tooling may be collapsible, wash-out, shape memory, or any other suitable means. It is the design objectives and structural requirements that will drive the various shapes needed for each application which can be used in accordance with the teaching disclosed herein.

[0058] FIG. 6 is a sectional side view of another embodiment of a method for manufacturing a rib-stiffened composite structure 10. FIG. 6 shows the starting point which is simply the composite face sheet 12 having a continuous reinforcing fiber in a polymer matrix.

[0059] FIG. 7 shows an injector 33 depositing an extruded polymer core 34 in the grid pattern on the composite face sheet 12. As taught before, the grid pattern can comprise any number of parallel or non-parallel lines crossing over a second series of parallel or non-parallel lines wherein material voids are once again formed in the spaces between the series of lines/ribs. The extruded polymer core as shown here is deposited using a plurality of layers 35a-35i by fused-filament fabrication. It is understood by those skilled in the art that one layer or any “n” number of layers may be used to create such a core structure. It is also understood by those skilled in the art that other forms of additive manufacturing or traditional manufacturing may be used to create the core 34.

[0060] Once the core material 34 of the ribs are formed, FIG. 8 shows a representative means to deposit a composite rib-cap 12 upon an upper surface 36 of the extruded polymer core. Here, the in-situ consolidation process is used where a prepreg material 38 is automatically dispenses and consolidated by the use of a roller 40 and various heaters 42. It is understood that this depiction has been simplified for ease of understanding. The roller 40 may be one or any number and shape of rollers as needed. Likewise, the heater may be one or any number of types of heaters, such as heated air or directed light energy heaters.

[0061] The deposition of the prepreg may be done with one layer or many layers 39a-39c as is shown completed in FIG. 9. Thus, it is understood by those skilled in the art that one or any “n” number of layers can be utilized.

[0062] Furthermore, as best shown in FIG. 10, the fibers of the continuous reinforcing fiber of the polymer matrix of the composite rib cap are oriented in a direction along the first and second series of parallel lines of the grid pattern of the extruded polymer core as taught previously. This is done by laying the prepreg along the direction 17 and then also laying it along the direction 19. There will be overlap at the nodes 44 of the ribs, where the prepreg in direction 17 overlaps the prepreg in the direction 19. However, the prepreg thickness is relatively thin such that any buildup of overlap does not then become undesirably thick and wasteful.

[0063] In regards to FIGS. 11A-11D, in the case of thick rib caps 14 at the junction 44 or where a uniform rib height is needed, every other layer of rib cap prepreg 39n can be cut and restarted at the node as previously stated. For example, when prepreg is being laid down in the direction 17 in FIG. 11A, it may be stopped and started so no prepreg is disposed on or at the junction 44. Then, in FIG. 11B prepreg can be laid down in direction 19 that goes through the junction 44. Next in FIG. 11C, when prepreg is again laid down in direction 17 it does not stop and start at junction 44 but instead is laid down through junction 44. Next IN FIG. 11D, prepreg is laid down in direction 19 but stops and starts at junction 44. In this manner, the process can be repeated again and again such that junction 44 never becomes overly thick in comparison to the rest of the path along the directions 17 and 19. Accordingly, each junction has alternating continuous prepreg layers of the first series and second series of paths forming a junction of similar thickness to the rest of the first and second series of paths.

[0064] For all embodiments taught herein, to aid in bonding between the composite face sheet and rib cap to then the core material of the ribs, the polymer used in the polymer matrix of the face sheet and rib cap can be the same or compatible polymer used in the core material. This provides homogeneity between the material properties of the rib-stiffened composite structure to then prevent delamination and other various mismatches of coefficients of thermal expansion.

[0065] Although several embodiments have been described in detail for purposes of illustration, various modifications may be made to each without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.

NUMERALS

[0066] 10 rib-stiffened composite structure [0067] 12 composite face sheet [0068] 13 distance [0069] 14 composite rib cap [0070] 15 grid pattern [0071] 16 first series of parallel lines/paths/ribs [0072] 17 fiber direction, first series or ribs [0073] 18 second series of parallel lines/paths/ribs [0074] 19 fiber direction, second series of ribs [0075] 20 voids between ribs [0076] 22 first mold [0077] 23 portion, first mold [0078] 24 hollow space [0079] 26 second mold [0080] 27 backside of composite face sheet [0081] 28 frontside of composite face sheet [0082] 30 core material [0083] 32 side walls, core material [0084] 33 injector [0085] 34 extruded polymer core material [0086] 35a-i layers of extruded polymer core [0087] 36 upper surface of extruded polymer core [0088] 38 prepreg material [0089] 39a-c layers of prepreg material [0090] 40 roller [0091] 42 heater or heaters [0092] 44 rib cap junction/nodes