# US 2014/0196837 A1 · Method of integrally forming ribs in a composite panel > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2014/0196837 A1 - Document ID: US20140196837A1 - Status: Published application - Kind: A1 - Application number: 13/741,417 - Filed: 2013-01-15 - Published: 2014-07-17 - Earliest claimed: 2013-01-15 - Assignees: GM Global Technology Operations LLC - Applicants: GM Global Technology Operations LLC - Inventors: Joseph M. Polewarczyk; Paul E. Krajewski - Web page: https://patentgrep.com/patent/US20140196837A1 ## CPC - B29C 65/002: {Joining methods not otherwise provided for} - B29D 24/005: {the structure having joined ribs, e.g. honeycomb} - Y10T 156/1002: with permanent bending or reshaping or surface deformation of self sustaining lamina - 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) - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method of integrally forming a composite rib structure includes positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, and the fiber sheet including a plurality of fibers oriented along a first common direction. The method further including extending the wedge-shaped protrusion through the first fiber sheet such that a subset of the plurality of fibers are displaced about the protrusion and into each of the respective first channel and second channel; applying a resin within each of respective first channel and second channel to the plurality of fibers; pre-curing the resin to form a pre-preg rib structure within the channels; and removing the pre-preg rib structure from the pre-preg mold. ## Claims ### Claim 1 A method of integrally forming a composite rib structure comprising: positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, the fiber sheet including a plurality of fibers oriented along a first common direction; extending the wedge-shaped protrusion through the first fiber sheet such that a subset of the plurality of fibers is displaced about the protrusion and into each of the respective first channel and second channel; applying a resin within each of the respective first channel and second channel to the plurality of fibers; pre-curing the resin to form a pre-preg rib structure within the channels; and removing the pre-preg rib structure from the pre-preg mold. ### Claim 2 (depends on 1) The method of claim 1, further comprising: positioning a second fiber sheet on the pre-preg mold prior to applying the resin, the second fiber sheet including a second plurality of fibers oriented along a second common direction, the pre-preg mold including a third channel and a fourth channel separated by the wedge-shaped protrusion and each disposed at an angle to the respective first channel and second channel; extending the wedge-shaped protrusion through the second fiber sheet such that a subset of the second plurality of fibers are displaced about the protrusion and into each of the respective third channel and fourth channel; and applying a resin within each of respective third channel and fourth channel to the plurality of fibers. ### Claim 3 (depends on 2) The method of claim 2, wherein the wedge-shaped protrusion includes at least one of a conical portion and a pyramidal portion, and wherein the at least one of a conical portion and a pyramidal portion is configured to pierce through the first fiber sheet and the second fiber sheet. ### Claim 4 (depends on 1) The method of claim 1, further comprising: inserting the pre-preg rib structure into a part mold; overlaying the pre-preg rib structure with a composite pre-preg panel; curing the pre-preg rib structure and the composite pre-preg panel within the part mold to fuse the pre-preg rib structure with the composite pre-preg panel. ### Claim 5 (depends on 3) The method of claim 3, wherein curing the pre-preg part within the part mold includes heating and applying pressure to the pre-preg part. ### Claim 6 (depends on 1) The method of claim 1, wherein the step of extending the wedge-shaped protrusion through the first fiber sheet is characterized by not severing any of the plurality of fibers. ### Claim 7 (depends on 1) The method of claim 1, wherein the plurality of fibers of the first fiber sheet are carbon fibers. ### Claim 8 A method of integrally forming a composite panel with a composite rib structure comprising: positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, the fiber sheet including a plurality of fibers oriented along a first common direction; extending the wedge-shaped protrusion through the first fiber sheet such that a subset of the plurality of fibers is displaced about the protrusion and into each of the respective first channel and second channel; applying a resin within each of the respective first channel and second channel to the plurality of fibers; pre-curing the resin to form a pre-preg rib structure within the channels; and removing the pre-preg rib structure from the pre-preg mold; inserting the pre-preg rib structure into a part mold; overlaying the pre-preg rib structure with a composite pre-preg panel; and curing the pre-preg rib structure and the composite pre-preg panel within the part mold to fuse the pre-preg rib structure with the composite pre-preg panel. ### Claim 9 (depends on 8) The method of claim 8, further comprising: positioning a second fiber sheet on the pre-preg mold prior to applying the resin, the second fiber sheet including a second plurality of fibers oriented along a second common direction, the pre-preg mold including a third channel and a fourth channel separated by the wedge-shaped protrusion and each disposed at an angle to the respective first channel and second channel; extending the wedge-shaped protrusion through the second fiber sheet such that a subset of the second plurality of fibers are displaced about the protrusion and into each of the respective third channel and fourth channel; and applying a resin within each of respective third channel and fourth channel to the plurality of fibers. ### Claim 10 (depends on 9) The method of claim 9, wherein the wedge-shaped protrusion includes at least one of a conical portion and a pyramidal portion, and wherein the at least one of a conical portion and a pyramidal portion is configured to pierce through the first fiber sheet and the second fiber sheet. ### Claim 11 (depends on 8) The method of claim 8, wherein curing the pre-preg part within the part mold includes heating and applying pressure to the pre-preg part. ### Claim 12 (depends on 8) The method of claim 8, wherein the step of extending the wedge-shaped protrusion through the first fiber sheet is characterized by not severing any of the plurality of fibers. ### Claim 13 (depends on 8) The method of claim 8, wherein the plurality of fibers of the first fiber sheet are carbon fibers. ### Claim 14 A method of integrally forming a composite panel with a composite rib structure comprising: positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, the fiber sheet including a plurality of fibers oriented along a first common direction; positioning a second fiber sheet on the pre-preg mold prior to applying the resin, the second fiber sheet including a second plurality of fibers oriented along a second common direction, the pre-preg mold including a third channel and a fourth channel separated by the wedge-shaped protrusion and each disposed at an angle to the respective first channel and second channel; extending the wedge-shaped protrusion through each of the first fiber sheet and second fiber sheet such that a subset of the plurality of fibers is displaced about the protrusion and into each of the respective first channel, second channel, third channel, and fourth channel; applying a resin within each of the respective first channel, second channel, third channel, and fourth channel to the plurality of fibers; pre-curing the resin to form a pre-preg rib structure within the channels; and removing the pre-preg rib structure from the pre-preg mold; inserting the pre-preg rib structure into a part mold; overlaying the pre-preg rib structure with a composite pre-preg panel; and curing the pre-preg rib structure and the composite pre-preg panel within the part mold to fuse the pre-preg rib structure with the composite pre-preg panel. ### Claim 15 (depends on 14) The method of claim 14, wherein the wedge-shaped protrusion includes at least one of a conical portion and a pyramidal portion, and wherein the at least one of a conical portion and a pyramidal portion is configured to pierce through the first fiber sheet and the second fiber sheet. ### Claim 16 (depends on 14) The method of claim 14, wherein curing the pre-preg part within the part mold includes heating and applying pressure to the pre-preg part. ### Claim 17 (depends on 14) The method of claim 14, wherein the step of extending the wedge-shaped protrusion through the first fiber sheet is characterized by not severing any of the plurality of fibers. ### Claim 18 (depends on 14) The method of claim 14, wherein the plurality of fibers of the first fiber sheet are carbon fibers.