Structural Inserts for Honeycomb Structures

• US 20150298423A1
• Filed: 09/03/2013
• Published: 10/22/2015
• Est. Priority Date: 09/03/2013
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Holemans, Peter
• Granted Patent: US 9,981,446 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B32B 15/04 comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a bituminous or tarry layer B32B11/08; next to a water-setting substance layer B32B13/06; next to a glass layer B32B17/061; next to a cellulosic plastic layer B32B23/042
• CPC Class Codes: B32B 2250/03 3 layers
• CPC Class Codes: B32B 2250/40 Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2419/00 Buildings or parts thereof walls, panels B32B2607/00
• CPC Class Codes: B32B 2605/08 Cars
• CPC Class Codes: B32B 2605/10 Trains
• CPC Class Codes: B32B 2605/12 Ships
• CPC Class Codes: B32B 2605/16 Submarines
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 2607/00 Walls, panels
• CPC Class Codes: B32B 3/06 for securing layers together; for attaching the product to another member, e.g. to a support , or to another product, e.g. groove/tongue, interlocking
• CPC Class Codes: B32B 3/08 characterised by added members at particular parts layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B33Y 80/00 Products made by additive manufacturing
• CPC Class Codes: B64C 1/00 Fuselages; Constructional features common to fuselages, wings, stabilising surfaces or the like
• CPC Class Codes: B64C 1/06 : Frames; Stringers; Longerons ; Fuselage sections
• CPC Class Codes: B64C 1/12 : Construction or attachment of skin panels
• CPC Class Codes: B64C 1/18 : Floors
• CPC Class Codes: B64C 2001/0072 : from composite materials
• CPC Class Codes: F16B 5/01 : by means of fastening elements specially adapted for honeycomb panels
• CPC Class Codes: Y02T 50/40 : Weight reduction

Abstract

A method and apparatus for manufacturing a sandwich structure. A cavity is formed in a core of the sandwich structure. A structural insert is placed into the cavity. The structural insert comprises a first number of parts configured to receive a load and a second number of parts assembled with the first number of parts to form the structural insert.

Claims

1. An apparatus comprising:

a first number of parts configured to receive a load; and

a second number of parts configured to be assembled with the first number of parts to form a structural insert for a sandwich structure.

2. The apparatus of claim 1 further comprising:

a cavity in the sandwich structure, wherein the cavity is configured to receive the structural insert.

3. The apparatus of claim 1, wherein the sandwich structure comprises:

a first layer;

a second layer; and

a core having a cavity configured hold the structural insert.

4. The apparatus of claim 1, wherein the structural insert is configured to spread the load across a surface of the structural insert.

5. The apparatus of claim 1, wherein a core is selected from one of a foam core, a honeycomb core, or a composite core.

6. The apparatus of claim 1, wherein the structural insert is manufactured using an additive manufacturing process.

7. The apparatus of claim 1, wherein a density for the first number of parts is different over different portions of the first number of parts based on the load expected.

8. The apparatus of claim 1, wherein the sandwich structure is a honeycomb sandwich panel and the honeycomb sandwich panel is located in a structure selected from one of a floor, a closet, and a wall.

9. The apparatus of claim 1, wherein a first layer and a second layer are a number of layers of laminate comprising materials selected from a least one of steel, aluminum, a composite material, fiberglass, or carbon fiber.

10. The apparatus of claim 1, wherein the first number of parts and the second number of parts are comprised of a number of materials selected from at least one of a composite material, a metal, aluminum, titanium, graphite, plastic, polycarbonate, glass, fiberglass, wood, concrete, steel, carbon fiber, para-aramid synthetic fiber, a carbon fiber reinforced thermoplastic, or a carbon fiber thermoset polymer.

11. The apparatus of claim 1, wherein the sandwich structure is located in a platform selected from one of a mobile platform, a stationary platform, a land-based structure, an aquatic-based structure, a space-based structure, an aircraft, a surface ship, a tank, a personnel carrier, a train, a spacecraft, a space station, a satellite, a submarine, an automobile, a power plant, a bridge, a dam, a house, a manufacturing facility, and a building.

12. A honeycomb panel comprising:

a first skin;

a second skin;

a honeycomb core located between the first skin and the second skin; and

a structural insert located in a cavity in the honeycomb core, wherein the structural insert has a first number of parts configured to receive a load and a second number of parts.

13. The honeycomb panel of claim 12, wherein the structural insert is manufactured using an additive manufacturing process.

14. The honeycomb panel of claim 12, wherein a density of the first number of parts is different over different portions of the first number of parts based on the load expected.

15. A method for manufacturing a sandwich structure, the method comprising:

forming a cavity in a core of the sandwich structure; and

placing a structural insert into the cavity, wherein the structural insert comprises a first number of parts configured to receive a load and a second number of parts assembled with the first number of parts to form the structural insert.

16. The method of claim 15 further comprising:

attaching the core to a first layer;

forming the cavity in the core; and

attaching a second layer to at least one of the core or the structural insert after placing the structural insert into the cavity.

17. The method of claim 15 further comprising:

identifying the load anticipated for the sandwich structure; and

designing the first number of parts and the second number of parts such that the first number of parts receives the load when assembled to form the structural insert within the sandwich structure.

18. The method of claim 15, wherein a density of the first number of parts is different over different portions of the first number of parts based on the load expected.

19. The method of claim 15, wherein the sandwich structure is a honeycomb sandwich panel and the honeycomb sandwich panel is located in a structure selected from one of a floor, a closet, and a wall.

20. A method for handling a load in an aircraft, the method comprising:

receiving the load at a honeycomb panel comprising a first skin, a second skin, a honeycomb core located between the first skin and the second skin, and a structural insert located in a cavity in the honeycomb core, wherein the structural insert has a first number of parts configured to receive the load and a second number of parts; and

spreading the load through the first number of parts in the structural insert.