# US 2013/0095284 A1 · Composite structure and core positioning ply

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- Number: US 2013/0095284 A1
- Document ID: US20130095284A1
- Status: Published application
- Kind: A1
- Application number: 13/274,690
- Filed: 2011-10-17
- Published: 2013-04-18
- Earliest claimed: 2011-10-17
- Assignees: Sikorsky Aircraft Corporation
- Inventors: Jonathan Bremmer; Jeffrey G. Sauer; Edward Joseph Fabian; Paul H. Denavit; Darryl Mark Toni; William E. Hovan, III
- Web page: https://patentgrep.com/patent/US20130095284A1

## CPC

- B29C 70/34: and shaping or impregnating by compression {, i.e. combined with compressing after the lay-up operation}
- B29C 70/302: {Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination}
- B29C 70/865: {completely encapsulated}
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B29C 65/00: Joining {or sealing} of preformed parts {, e.g. welding of plastics materials}; Apparatus therefor {(general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326)}
- B29C 65/483: {Reactive adhesives, e.g. chemically curing adhesives}
- B29C 66/1142: {Single butt to butt joints}
- B29C 66/721: {Fibre-reinforced materials (B29C66/729 takes precedence)}
- B29C 70/342: {using isostatic pressure}
- Y10T 428/24149: Honeycomb-like
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

A composite structure includes a first laminate, a second laminate, and at least one core component located between the first laminate and the second laminate. The at least one core component includes a honeycomb core and at least one locking ply extending from the honeycomb core between the first laminate and the second laminate. The at least one locking ply is configured such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.

## Claims

### Claim 1

A composite structure comprising:
a first laminate;
a second laminate; and
at least one core component located between the first laminate and the second laminate including:
a honeycomb core; and
at least one locking ply extending from the honeycomb core between the first laminate and the second laminate such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.

### Claim 2 (depends on 1)

The composite structure of claim 1, wherein the at least one locking ply is secured to the honeycomb core via pre-curing.

### Claim 3 (depends on 1)

The composite structure of claim 1, wherein the at least one locking ply includes curvature to conform to a shape of at least one of the first laminate and the second laminate.

### Claim 4 (depends on 1)

The composite structure of claim 1, wherein the at least one locking ply is two or more locking plies.

### Claim 5 (depends on 1)

The composite structure of claim 1, wherein the at least one locking ply is one of a prepreg or wet layup material.

### Claim 6 (depends on 1)

The composite structure of claim 1, wherein the at least one locking ply is retained directly between the first laminate and the second laminate.

### Claim 7

A method of forming a composite structure comprising:
positioning a first laminate in a molding tool;
positioning a core element in the molding tool, the core element including at least one locking ply extending therefrom;
positioning a second laminate over the core element; and
applying pressure to the second laminate thereby retaining the at least one locking ply between the first laminate and the second laminate and preventing movement of the core element.

### Claim 8 (depends on 7)

The method of claim 7, further comprising securing the at least one locking ply to the honeycomb core via pre-curing.

### Claim 9 (depends on 7)

The method of claim 7, wherein the at least one locking ply is two or more locking plies.

### Claim 10 (depends on 7)

The method of claim 7, wherein the at least one locking ply is one of a prepreg or wet layup material.

### Claim 11 (depends on 7)

The method of claim 7, wherein the at least one locking ply is retained directly between the first laminate and the second laminate.

### Claim 12 (depends on 7)

The method of claim 7, wherein the pressure is about 65 psi.