Hybrid fiberglass composite structures and methods of forming the same

• US 20060219845A1
• Filed: 03/31/2005
• Published: 10/05/2006
• Est. Priority Date: 03/31/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kismarton, Max U.
• Granted Patent: US 7,740,932 B2
• Time in Patent Office: Days
• US Class Current: 244/133
• CPC Class Codes: 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
• CPC Class Codes: B29K 2709/08 Glass
• CPC Class Codes: B32B 17/04 bonded with or embedded in a plastic substance
• CPC Class Codes: B32B 2250/05 5 or more layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2305/076 Prepregs
• CPC Class Codes: B32B 2307/558 Impact strength, toughness
• CPC Class Codes: B32B 2307/704 Crystalline
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2307/718 Weight, e.g. weight per square meter
• CPC Class Codes: B32B 2315/085 Glass fiber cloth or fabric
• CPC Class Codes: B32B 2363/00 Epoxy resins
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 2605/12 Ships
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/36 : comprising polyesters
• CPC Class Codes: B32B 27/38 : comprising epoxy resins
• CPC Class Codes: B32B 3/12 : characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 37/146 : whereby one or more of the layers is a honeycomb structure
• CPC Class Codes: B32B 5/024 : Woven fabric
• CPC Class Codes: B32B 5/26 : another layer next to it also being fibrous or filamentary relative arrangement of fibres or filaments of different layers B32B5/12
• CPC Class Codes: B32B 5/28 : impregnated with or embedded in a plastic substance not used
• CPC Class Codes: Y10T 428/249924 : Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity

Abstract

Hybrid fiberglass composite structures and methods for forming the same are disclosed. In one embodiment, a hybrid fiberglass composite structure includes a first laminate substrate and a second opposing laminate substrate. At least one of the first laminate substrate and the second laminate substrate includes at least one polymer fiber layer and at least one glass fiber layer. A cellular core structure is interposed between the first laminate substrate and the second laminate substrate and fixedly coupled to the first laminate substrate and the second laminate substrate.

Claims

1. A hybrid fiberglass composite structure, comprising:

a first laminate substrate and an opposing second laminate substrate, wherein at least one of the first laminate substrate and the second laminate substrate further include at least one polymer fiber layer and at least one glass fiber layer; and

a cellular core structure interposed between the first laminate substrate and the second laminate substrate and coupled to the first laminate substrate and the second laminate substrate.

2. The fiberglass composite structure of claim 1, wherein at least one of the first laminate substrate and the second laminate substrate further comprise a first resin layer and a second resin layer.

3. The fiberglass composite structure of claim 2, wherein at least one of the first resin layer and the second resin layer further comprise epoxy resin layers.

4. The fiberglass composite structure of claim 1, wherein at least one of the polymer fiber layers further comprises at least one of a polyethylene fiber layer and a liquid crystalline polymer fiber layer.

5. The fiberglass composite structure of claim 1, wherein at least one of the first laminate substrate and the second laminate substrate include pre-assembled “

pre-preg”

materials.

6. The fiberglass composite structure of claim 1, wherein at least one of the first and the second laminate substrates includes glass fiber layers and polymer fiber layers in a ratio of approximately about one to three.

7. The fiberglass composite structure of claim 1, wherein at least one of the first laminate substrate and the second laminate substrate includes glass fiber layers and polymer fiber layers in approximately equal proportions.

8. The fiberglass composite structure of claim 1, wherein the cellular core structure further comprises a honeycomb core structure.

9. A method of forming a fiberglass composite structure, comprising:

forming a first laminate substrate and an opposing second laminate substrate, wherein at least one of the first laminate substrate and the second laminate substrate further comprises at least one glass fiber layer and at least one polymer fiber layer;

positioning a cellular core structure between the first laminate substrate and the second laminate substrate;

fixedly coupling the first laminate substrate and the second laminate substrate to the cellular core structure; and

integrating the composite structure into the desired structural component.

10. The method of claim 9, wherein forming a first laminate substrate and a second laminate substrate further comprises bonding the glass fiber layers to the polymer fiber layers.

11. The method of claim 10, wherein forming a first laminate substrate and an opposing second laminate substrate further comprises impressing the first laminate substrate and the second laminate substrate into a desired contour shape.

12. The method of claim 11, wherein impressing the first laminate substrate and the second laminate substrate into a desired contour shape includes positioning the first laminate substrate and the second substrate on a forming die having the desired contour shape.

13. The method of claim 10, wherein bonding the glass fiber layer to the polymer fiber layer further comprises bonding the glass fiber layer to the polymer fiber layer with at least one of a first resin layer and a second resin layer.

14. The method of claim 9, wherein positioning a cellular core structure includes positioning a honeycomb core structure between the first laminate substrate and the second laminate substrate.

15. The method of claim 9, wherein integrating the composite structure includes incorporating the structure into an aircraft secondary structural component.

16. The method of claim 9, wherein fixedly coupling the first laminate substrate and the second laminate substrate to the cellular core structure further comprises bonding the first laminate substrate and the second laminate substrate to the cellular core structure

17. The method of claim 16, wherein bonding the first laminate substrate and the second laminate substrate to the cellular core structure further comprises adhesively bonding the first laminate substrate and the second laminate substrate to the cellular core structure.

18. The method of claim 16, wherein bonding the first laminate substrate and the second laminate substrate to the cellular core structure further comprises thermally fusing the first laminate substrate and the second laminate substrate to the cellular core structure.

19. An aerospace vehicle, comprising:

a fuselage;

wing assemblies and an empennage operatively coupled to the fuselage; and

a composite structure incorporated into at least one of the fuselage, wing assemblies and empennage, the structure further comprising;

a first laminate substrate and an opposing second laminate substrate, wherein at least one of the first laminate substrate and the second laminate substrate further include at least one polymer fiber layer and at least one glass fiber layer; and

a cellular core structure interposed between the first laminate substrate and the second laminate substrate and fixedly coupled to the first laminate substrate and the second laminate substrate.

20. The aerospace vehicle of claim 19, wherein at least one of the polymer fiber layers includes at least one of a polyethylene fiber layer and a liquid crystalline polymer fiber layer.