Composite panel including a tailored composite core via additive manufacturing
AssigneesGM Global Technology Operations LLC, Pratt & Miller Engineering and Fabrication, Inc.
InventorsRyan GERGELY, Gary Alan LATHAM, Andrew Thomas CUNNINGHAM, David A. OKONSKI
Life of this patent
Estimating the term…
Abstract
A composite panel comprises a first skin and a second skin. A core is arranged between and attached to the first skin and the second skin. The core includes Z zones that are 3D printed using a thermoplastic material. Each of the Z zones abuts and is connected to another one of the Z zones. Each of the Z zones has one of D densities and at least one of the Z zones had a different density that another one of the Z zones. Z and D are integers greater than one.
Claims16
A composite panel comprising:
- a first skin;
- a second skin;
- and
- a core arranged between and attached to the first skin and the second skin,
- wherein the core includes at least one layer of Z zones that are 3D printed using a thermoplastic material,
- wherein each of the Z zones abuts and is connected to another one of the Z zones,
- wherein each of the Z zones has one of D densities and at least one of the Z zones has a different density that another one of the Z zones,
- wherein each of the Z zones includes an infill pattern having paths along borders between abutting ones of the Z zones having different densities,
- wherein the paths between abutting ones of the Z zones having different densities are located in overlap regions,
- wherein the overlap regions are discontinuous along the borders, and
- where Z and D are integers greater than one.
6-8. (canceled)
A method for making a composite panel comprising:
- modelling expected loads on a composite panel during use, wherein the composite panel includes a core arranged between and attached to a first skin and a second skin;
- identifying locations of Z zones in the core, wherein each of the Z zones includes a border abutting and connected to another one of the Z zones;
- and
- 3D printing the Z zones using a thermoplastic material,
- wherein each of the Z zones has one of D densities and at least one of the Z zones has a different density that another one of the Z zones,
- wherein each of the Z zones includes an infill pattern having paths along borders between abutting ones of the Z zones having different densities,
- wherein the paths between abutting ones of the Z zones having different densities are located in overlap regions,
- wherein the overlap regions are discontinuous along the borders, and
- where Z and D are integers greater than one.
16-18. (canceled)
Dependencies are inferred from the claim text.