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US 12,623,431 B2Granted
Foam sheet core for composite sandwich structures and method of making the same
AssigneeThe Boeing Company
InventorsXiaoxi Wang, Gary E. Georgeson
Life of this patent
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Abstract
A foam sheet core, including a plurality of foam sheet walls defining an array of hollow cells, wherein the plurality of foam sheet walls are bonded together to form the array of hollow cells, each of the plurality of foam sheet walls has a thickness from about 0.002 inches to about 0.08 inches, and each of the plurality of foam sheet walls has an average height from about 0.05 inches to about 5 inches.
Claims20
A method of making a foam sheet core for a composite sandwich structure, comprising:
- stacking two or more foam sheets into a foam sheet block;
- fusion bonding the stacked foam sheet block;
- slicing the bonded foam sheet block into one or more strips of foam sheet;
- and
- expanding the one or more strips of foam sheet into a foam sheet core,
- wherein the two or more foam sheets comprise a foamed polymer with a relative density to solid from about 30% to about 80% and a melting temperature from about 270° F. to about 800° F., and
- wherein the foam sheet core comprises a plurality of foam sheet walls fusion bonded together to form an array of hollow cells.
4 more elements
A method of making a composite sandwich structure comprising:
- providing one or more foam sheet cores;
- and
- fusion bonding the one or more foam sheet cores to one or more skin panels to form the composite sandwich structure,
- wherein the one or more foam sheet cores comprise a plurality of foam sheet walls fusion bonded together to form an array of hollow cells, and
- where the plurality of foam sheet walls comprise a foamed polymer with a relative density to solid from about 30% to about 80% and a melting temperature from about 270° F. to about 800° F.
2 more elements
Dependencies are inferred from the claim text.