# US 2013/0154154 A1 · Composite structures having cored members

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- Number: US 2013/0154154 A1
- Document ID: US20130154154A1
- Status: Published application
- Kind: A1
- Application number: 13/533,286
- Filed: 2012-06-26
- Published: 2013-06-20
- Earliest claimed: 2011-06-27
- Inventors: William L. Rodman
- Web page: https://patentgrep.com/patent/US20130154154A1

## CPC

- B29C 70/549: {Details of caul plates, e.g. materials or shape}
- B29C 33/505: {cores or mandrels, e.g. inflatable (B29C33/0016 takes precedence; for winding and joining B29C53/824; for supporting articles during joining B29C66/634; flexible cores for vulcanizing tyres B29D30/0654)}
- B29C 43/003: {characterised by the choice of material}
- B29C 51/14: using multilayered preforms or sheets
- B29C 70/44: using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C 70/682: {Preformed parts characterised by their structure, e.g. form}
- B29L 2022/00: Hollow articles (tubular articles B29L2023/00; pneumatic tyres B29L2030/00)
- 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)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with cored members embedded there between. The wetted fibers are arranged on pressurizable members and may be configured to include internal structural features, such as shear webs. A reinforcement stiffener may be located adjacent to at least one of the pressurizable members and the wetted fibers that form the internal structural feature. The cored members may be selectively located on various interior and exterior regions or surfaces of the composite structure.

## Claims

### Claim 1

A method of making a composite structure within a tool, the method comprising:
arranging a plurality of pressurizable members within the tool, each of the pressurizable members having a desired shape before pressurization that includes an outer surface and an inner surface defining a volumetric region, each of the pressurizable members further having an opening to permit internal pressurization thereof, wherein at least one of the pressurizable members includes a recessed region;
arranging a first plurality of fiber plies onto at least one surface of each of the plurality of pressurizable members, wherein at least some of the first fiber plies are placed onto the recessed region to substantially conform therewith;
placing a cored member onto the recessed, first fiber plies, the cored member complementarily configured to conform to the recessed portion;
arranging a second plurality of fiber plies onto the first plurality of fiber plies and onto the cored member to substantially form the composite structure;
pressurizing an outer surface of the composite assembly with a first pressure; and
pressurizing the inner surface of the pressurizable members with a second pressure, wherein the first pressure and the second pressure operate to compress the fiber plies without crushing the cored member.

### Claim 2 (depends on 1)

The method of claim 1, further comprising increasing a chamfer angle of the cored member along one or more edges of the cored member.

### Claim 3 (depends on 1)

The method of claim 1 wherein the first plurality of fiber plies forms an exterior surface of the composite structure.

### Claim 4 (depends on 1)

The method of claim 1 wherein the first plurality of fiber plies forms an interior surface of the composite structure.