# US 8,784,592 B2 · Method for manufacturing a core composite provided with cover layers on both sides

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- Number: US 8,784,592 B2
- Document ID: US8784592B2
- Status: Granted
- Kind: B2
- Application number: 12/736,301
- Filed: 2009-02-20
- Published: 2011-01-20
- Granted: 2014-07-22
- Earliest claimed: 2008-04-15
- Assignees: Airbus Operations GmbH
- Applicants: Michael Kolax; Wolf-Dietrich Dolzinski
- Inventors: Michael Kolax; Wolf-Dietrich Dolzinski
- Web page: https://patentgrep.com/patent/US8784592B2

## CPC

- B29C 70/086: {and with one or more layers of pure plastics material, e.g. foam layers (applying a non-preformed coating, e.g. a gel-coat, B29C37/0025; with foam blocks B29C70/86)}
- B29D 99/0021: {provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix}
- B32B 3/12: characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
- B32B 5/024: {Woven fabric}
- B32B 5/026: {Knitted fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/05: the layers not being connected over the whole surface, e.g. discontinuous connection or patterned connection (using interposed adhesives or bonding materials applied in spaced arrangements B32B7/14)
- B32B 7/14: applied in spaced arrangements, e.g. in stripes
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 29/02: next to a fibrous or filamentary layer
- B32B 37/146: {whereby one or more of the layers is a honeycomb structure}
- B29K 2063/00: Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material
- B29K 2105/246: {Uncured, e.g. green}
- B29K 2707/04: Carbon
- B29L 2031/608: {Honeycomb structures}
- B32B 37/0007: {involving treatment or provisions in order to avoid deformation or air inclusion, e.g. to improve surface quality}
- B32B 38/10: Removing layers, or parts of layers, mechanically or chemically
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/028: Paper layer
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2307/50: having particular mechanical properties
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2605/18: Aircraft
- Y10T 156/1025: to form undulated to corrugated sheet and securing to base with parts of shaped areas out of contact
- Y10T 156/103: Encasing or enveloping the configured lamina
- Y10T 156/1033: Flexible sheet to cylinder lamina
- Y10T 156/1051: by folding
- Y10T 428/24149: Honeycomb-like
- Y10T 428/24157: Filled honeycomb cells [e.g., solid substance in cavities, etc.]
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The invention relates to a method for manufacturing flat, single or double curved core composites 1, 23 with at least one folded honeycomb core 4, 19. Prior to applying the initially not yet hardened cover layers 2, 3, 13, 22 a curable and later removable core filler material 15, 16 is introduced into full-length drainage-enabling channels 5, 6 of the folded honeycomb core 4, 19 in order to prevent telegraphing of the cover layers 2, 3, 13, 22 into the channels 5, 6 of the folded honeycomb core when arranging and/or hardening the cover layers 2, 3, 13, 22 and to produce edge-free and polygon-free surfaces of the core composite 1, 23. The core composites 1, 23 made according to the method have optimum structural mechanical properties, an ideal surface quality from the aerodynamic and aesthetic point of view, whereby a direct reprocessing of the core composites 1, 23 is possible without the need for further time and cost-intensive as well as in some circumstances weight-increasing finishing steps. With the method it is possible to manufacture in particular one-piece fuselage sections with wound core composites 1, 23 with a folded honeycomb 4, 19 as well as shell segments with laid cover layers 2, 3, 13, 22 for longitudinally divided (segmented) fuselage sections for large aircraft.

## Claims

### Claim 1

A method for manufacturing a core composite having a folded honeycomb core provided on both sides with cover layers wherein the folded honeycomb core has drainage-enabling channels running parallel to the cover layers, the method comprising:
arranging a lower cover layer formed with a wet prepreg material on a tool, introducing a core filler material at least in some areas into the folded honeycomb core,
arranging the at least one folded honeycomb core on the lower cover layer,
arranging the prepreg material on the folded honeycomb core to provide an upper cover layer,
hardening the entire core composite by applying pressure and/or temperature, and
removing the core filler material, wherein the core filler material is removed from the folded honeycomb core by melting or dissolving with a solvent.

### Claim 2 (depends on 1)

The method according to patent claim 1, wherein the lower and/or upper cover layer are stuck by an adhesive to the folded honeycomb core at least in some areas.

### Claim 3 (depends on 1)

The method according to patent claim 1, wherein an upper side and/or a lower side of the folded honeycomb core is/are filled out and shaped with the core filler material so that a polygon-free outer and inner contour of the mounted cover layers are set.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the tool is a rotating winding mandrel on which the prepreg material is wound to form at least a cover layer.

### Claim 5 (depends on 1)

The method according to claim 1, wherein the core composite is given a substantially shell-segment shaped geometry by the tool.

### Claim 6 (depends on 4)

The method according to claim 4, wherein the core composite is given a substantially hollow cylindrical geometry by the winding mandrel.

### Claim 7 (depends on 1)

The method according to claim 1, wherein as prepreg material is used a semi-finished product pre-impregnated with a curable plastics material with reinforcement fibres, wherein the pre-impregnated semi-finished product is only hardened after processing.

### Claim 8 (depends on 1)

The method according to claim 1, wherein the at least one folded honeycomb core is formed with a laminar surface reinforcement arrangement which is impregnated with a curable plastics material and is initially flat and then repeatedly folded.