# US 12,759,269 B2 · Composite panels and methods for manufacturing the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 12,759,269 B2 - Document ID: US12759269B2 - Status: Granted - Kind: B2 - Application number: 18/162,940 - Filed: 2023-02-01 - Published: 2024-08-01 - Granted: 2026-10-13 - Earliest claimed: 2023-02-01 - Assignees: General Electric Company - Applicants: General Electric Company - Inventors: Daniel Gene Dunn; Henry Charles McGuigan; Reza Sarrafi-Nour - Web page: https://patentgrep.com/patent/US12759269B2 ## CPC - B32B 18/00: Layered products essentially comprising ceramics, e.g. refractory products - C04B 35/565: based on silicon carbide - C04B 37/005: {consisting of glass or ceramic material} - C04B 37/008: {by means of an interlayer consisting of an organic adhesive, e.g. phenol resin or pitch} - B32B 2250/02: 2 layers - C04B 2235/616: Liquid infiltration of green bodies or pre-forms - C04B 2237/083: Carbide interlayers, e.g. silicon carbide interlayers - C04B 2237/086: Carbon interlayers - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE ## Abstract A method of assembling a composite panel includes disposing a pliable matrix material between a first side of a ceramic core structure and a ceramic matrix composite face sheet, wherein the ceramic core structure comprises a plurality of hollow cells defined by a plurality of walls extending from the first side of the ceramic core structure to a second side of the ceramic core structure opposite the first side; and densifying the pliable matrix material to bond the pliable matrix material with the ceramic core structure and the ceramic matrix composite face sheet. ## Claims ### Claim 1 A method of assembling a composite panel, the method comprising: disposing a pliable matrix material tape between a first side of a ceramic core structure and a ceramic matrix composite face sheet, wherein the ceramic core structure comprises a plurality of hollow cells defined by a plurality of walls extending from the first side of the ceramic core structure to a second side of the ceramic core structure opposite the first side, and wherein the pliable matrix material tape comprises chopped fibers; and densifying the pliable matrix material tape to bond the pliable matrix material tape with the ceramic core structure and the ceramic matrix composite face sheet. ### Claim 2 (depends on 1) The method of claim 1, wherein the pliable matrix material tape comprises a liquid carrier, a powder, and a polymeric binder. ### Claim 3 (depends on 2) The method of claim 2, wherein the powder comprises 10 percent to 90 percent carbon by weight, and wherein at least a portion of the chopped fibers comprises chopped carbon fibers. ### Claim 4 (depends on 2) The method of claim 2, wherein the powder comprises carbon and silicon carbide. ### Claim 5 (depends on 4) The method of claim 4, wherein the powder comprises 45 percent to 55 percent carbon by weight and 45 percent to 55 percent silicon carbide by weight. ### Claim 6 (depends on 2) The method of claim 2, wherein the liquid carrier comprises 5% to 15% by volume of the pliable matrix material tape. ### Claim 7 (depends on 1) The method of claim 1, wherein the pliable matrix material tape forms a fillet between the ceramic matrix composite face sheet and the ceramic core structure. ### Claim 8 (depends on 1) The method of claim 1, wherein densifying the pliable matrix material tape comprises densifying via melt infiltration. ### Claim 9 (depends on 8) The method of claim 8, wherein a densifying material is silicon, germanium, boron, or combinations thereof. ### Claim 10 (depends on 1) The method of claim 1, wherein densifying the pliable matrix material tape comprises densifying via chemical vapor infiltration. ### Claim 11 (depends on 1) The method of claim 1, wherein densifying the pliable matrix material tape comprises densifying via polymer infiltration and pyrolysis. ### Claim 12 (depends on 1) The method of claim 1, further comprising additively manufacturing the ceramic core structure. ### Claim 13 (depends on 1) The method of claim 1, wherein the plurality of walls are unitarily and monolithically formed to define the plurality of hollow cells. ### Claim 14 (depends on 1) The method of claim 1, further comprising disposing the pliable matrix material tape between the second side of the ceramic core structure and a ceramic matrix composite back sheet; and densifying the pliable matrix material tape to bond the pliable matrix material tape with the ceramic core structure and the ceramic matrix composite back sheet. ### Claim 15 A composite panel comprising: a ceramic core structure comprising a plurality of hollow cells defined by a plurality of walls extending from a first side of the ceramic core structure to a second side of the ceramic core structure, the second side opposite the first side; a ceramic matrix composite face sheet disposed at the first side of the ceramic core structure; and a matrix material tape that is densified and bonded with both the ceramic core structure and the ceramic matrix composite face sheet, wherein the matrix material tape comprises chopped fibers. ### Claim 16 (depends on 15) The composite panel of claim 15, wherein the matrix material tape comprises silicon carbide. ### Claim 17 (depends on 15) The composite panel of claim 15, further comprising: a ceramic matrix composite back sheet disposed at the second side of the ceramic core structure; and additional matrix material tape that is densified and bonded to both the ceramic core structure and the ceramic matrix composite back sheet. ### Claim 18 A composite panel comprising: an additively-manufactured ceramic core structure comprising a plurality of hollow cells defined by a plurality of walls extending from a top face to a bottom face; a ceramic matrix composite face sheet; and a conformal interface layer tape bonding the top face of the additively-manufactured ceramic core structure to the ceramic matrix composite face sheet, wherein the conformal interface layer tape comprises chopped fibers.