# US 10,766,595 B2 · Composite vehicle body > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 10,766,595 B2 - Document ID: US10766595B2 - Status: Granted - Kind: B2 - Application number: 15/682,844 - Filed: 2017-08-22 - Published: 2018-05-03 - Granted: 2020-09-08 - Earliest claimed: 2016-11-03 - Assignees: Continuous Composites Inc. - Applicants: Cc3D LLC - Inventors: Ryan C Stockett; Kenneth L. Tyler - Web page: https://patentgrep.com/patent/US10766595B2 ## CPC - B64C 1/12: Construction or attachment of skin panels - B29C 64/106: using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material - B29C 64/118: using filamentary material being melted, e.g. fused deposition modelling [FDM] - B29C 64/165: using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber - B29C 64/209: Heads; Nozzles - B29C 64/336: of two or more materials - B29C 70/382: {Automated fiber placement [AFP]} - B29C 70/56: Tensioning reinforcements before or during shaping - B29D 99/001: {Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings (articles with hollow walls B29D24/00)} - B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure - B32B 5/02: characterised by structural features of a {fibrous or filamentary} layer {(layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02)} - B32B 5/12: characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other} - B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)} - B32B 7/08: by mechanical means - B32B 15/043: {of metal (B32B15/01 takes precedence)} - B32B 19/06: next to a fibrous or filamentary layer - B32B 21/13: all layers being exclusively wood - B33Y 10/00: Processes of additive manufacturing - B33Y 30/00: Apparatus for additive manufacturing; Details thereof or accessories therefor - B33Y 80/00: Products made by additive manufacturing - B64C 1/06: Frames; Stringers; Longerons {; Fuselage sections} - B64C 1/08: Geodetic or other open-frame structures - B64C 1/26: Attaching the wing or tail units or stabilising surfaces - B64C 3/18: Spars; Ribs; Stringers - B64C 3/20: Integral or sandwich constructions - B64C 3/26: Construction, shape, or attachment of separate skins, e.g. panels - B64C 3/34: Tanks constructed integrally with wings, e.g. for fuel or water - B64F 5/10: Manufacturing or assembling aircraft, e.g. jigs therefor - B29C 70/302: {Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination} - B29K 2101/10: Thermosetting resins - B29L 2031/30: Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)} - B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)} - B29L 2031/3085: {Wings} - B32B 2255/02: on fibrous or filamentary layer - B32B 2260/021: Fibrous or filamentary layer - B32B 2260/04: Impregnation, embedding, or binder material - B32B 2262/0269: Aromatic polyamide fibres - B32B 2262/06: Vegetal fibres - B32B 2262/067: Wood fibres - B32B 2262/10: Inorganic fibres - B32B 2262/101: Glass fibres - B32B 2262/103: Metal fibres - B32B 2262/105: Ceramic fibres - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2262/14: Mixture of at least two fibres made of different materials - B32B 2307/202: Conductive - B32B 2307/50: having particular mechanical properties - B32B 2605/08: Cars - B32B 2605/12: Ships - B32B 2605/18: Aircraft - B62D 29/043: {Superstructures (B62D25/161 takes precedence)} - B64C 3/182: {Stringers, longerons} - B64C 3/185: {Spars} - B64C 3/187: {Ribs} - B64C 2001/0054: {Fuselage structures substantially made from particular materials} - B64C 2001/0072: {from composite materials} - B64C: AEROPLANES; HELICOPTERS - 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 (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B29D: PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE (making granules B29B9/00; making preforms B29B11/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING - B64F: GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR - 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 - B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES - B62D: MOTOR VEHICLES; TRAILERS (steering, or guiding on a desired track, of agricultural machines or implements A01B69/00; wheels, castors, axles, increasing wheel adhesion B60B; vehicle tyres, tyre inflation or tyre changing B60C; connections between vehicles of a train or the like B60D; vehicles for use on rail and road, amphibious or convertible vehicles B60F; suspension arrangements B60G; heating, cooling, ventilating or other air treating devices B60H; windows, windscreens, non-fixed roofs, doors or similar devices, protective coverings for vehicles not in use B60J; propulsion plant arrangements, auxiliary drives, transmissions, controls, instrumentation or dashboards B60K; electric equipment or propulsion of electrically-propelled vehicles B60L; power supply for electrically-propelled vehicles B60M; passenger accommodation not otherwise provided for B60N; adaptations for load transportation or to carry special loads or objects B60P; arrangement of signalling or lighting devices, the mounting or supporting thereof or circuits therefor, for vehicles in general B60Q; vehicles, vehicle fittings or vehicle parts not otherwise provided for B60R; servicing, cleaning, repairing, supporting, lifting, or manoeuvring, not otherwise provided for, B60S; brake arrangements, brake control systems or parts thereof B60T; air-cushion vehicles B60V; motor-cycles, accessories therefor B62J, B62K; testing of vehicles G01M) ## Abstract A vehicle body may have an internal skeleton forming a wing shape and a fuselage shape, and a skin fabricated in-situ over the internal skeleton. The skin may include a matrix material, and a plurality of continuous fibers at least partially coated with the matrix material. The plurality of continuous fibers may extend from the wing shape over the fuselage shape. ## Claims ### Claim 1 A vehicle body, comprising: an internal skeleton forming a wing shape and a fuselage shape; and a skin fabricated in-situ over the internal skeleton and including: a matrix material; and plurality of continuous fibers at least partially coated with the matrix material, the plurality of continuous fibers extending from the wing shape over the fuselage shape, wherein: the plurality of continuous fibers includes: a first plurality of continuous fibers arranged into a first layer that is generally parallel to an outer surface of the vehicle body; and a second plurality of continuous fibers arranged into a second layer overlapping the first layer; and the first plurality of continuous fibers extend normal to the outer surface from the first layer into the second layer to interlock the first and second layers. ### Claim 2 (depends on 1) The vehicle body of claim 1, wherein: the wing shape is a first wing shape; the internal skeleton further forms a second wing shape; and the plurality of continuous fibers in the skin on the first wing shape extend over the fuselage shape and into the skin on the second wing shape. ### Claim 3 (depends on 1) The vehicle body of claim 1, wherein: the internal skeleton includes at least one of ribs, spars, trusses, stringers, longerons, and bulkheads fabricated from the matrix material and a plurality of continuous fibers encased in the matrix material; and at least some of the plurality of continuous fibers of the at least one of ribs, spars, trusses, stringers, longerons, and bulkheads extend into and form a portion of the skin. ### Claim 4 (depends on 1) The vehicle body of claim 1, wherein the second plurality of continuous fibers pass orthogonally between adjacent fibers of the second plurality of continuous fibers. ### Claim 5 (depends on 1) The vehicle body of claim 1, wherein a density of the plurality of continuous fibers varies along a length of the wing shape. ### Claim 6 (depends on 1) The vehicle body of claim 1, wherein the matrix material includes multiple resins deposited at strategic locations in the skin. ### Claim 7 (depends on 6) The vehicle body of claim 6, wherein the multiple resins includes: a flexible resin at a trailing edge of the wing shape; and a stiffer resin away from the trailing edge. ### Claim 8 (depends on 6) The vehicle body of claim 6, wherein the multiple resins includes: a pyrolized resin at a leading edge of the wing shape; and an acrylated resin away from the leading edge. ### Claim 9 A vehicle body, comprising: an internal skeleton having at least one of ribs, spars, trusses, stringers, longerons, and bulkheads that together make a fuselage shape and a wing shape from a matrix material and a plurality of continuous fibers at least partially coated with the matrix material; and a skin fabricated in-situ over the internal skeleton, wherein the plurality of continuous fibers extends from the internal skeleton into the skin. ### Claim 10 (depends on 9) The vehicle body of claim 9, wherein the plurality of continuous fibers includes: a first plurality of continuous fibers arranged in generally parallel layers; and a second plurality of continuous fibers that extend normal to the generally parallel layers to interlock the generally parallel layers. ### Claim 11 (depends on 10) The vehicle body of claim 10, wherein the second plurality of continuous fibers pass orthogonally between adjacent fibers of the second plurality of continuous fibers. ### Claim 12 (depends on 9) The vehicle body of claim 9, wherein a density of the plurality of continuous fibers varies along a length of the wing shape. ### Claim 13 (depends on 9) The vehicle body of claim 9, wherein the matrix material includes multiple resins deposited at strategic locations in the skin. ### Claim 14 (depends on 13) The vehicle body of claim 13, wherein the multiple resins includes: a flexible resin at a trailing edge of the wing shape; and a stiffer resin away from the trailing edge. ### Claim 15 (depends on 13) The vehicle body of claim 13, wherein the multiple resins includes: a pyrolized resin at a leading edge of the wing shape; and an acrylated resin away from the leading edge. ### Claim 16 A vehicle body, comprising: an internal skeleton including matrix material and plurality of continuous fibers at least partially coated with the matrix material; and a skin fabricated in-situ over the internal skeleton, wherein: the plurality of continuous fibers includes: a first plurality of continuous fibers arranged into a first layer that is generally parallel to an outer surface of the vehicle body; and a second plurality of continuous fibers arranged into a second layer overlapping the first layer; and the first plurality of continuous fibers extend normal to the outer surface from the first layer into the second layer to interlock the first and second layers. ### Claim 17 (depends on 16) The vehicle body of claim 16, wherein the second plurality of continuous fibers pass orthogonally between adjacent fibers of the second plurality of continuous fibers. ### Claim 18 (depends on 16) The vehicle body of claim 16, wherein a density of the plurality of continuous fibers varies along a length of the skin. ### Claim 19 (depends on 16) The vehicle body of claim 16, wherein the matrix material includes multiple resins deposited at strategic locations in the skin.