Composite laminate

• US 5,806,796 A
• Filed: 03/04/1996
• Issued: 09/15/1998
• Est. Priority Date: 03/04/1995
• Status: Expired due to Term

• Current Assignee: Airbus Operations Limited (Airbus SE)
• Original Assignee: British Aerospace, Inc. (BAE Systems Plc)
• Inventors: Healey, Michael J.
• Primary Examiner(s): Barefoot, Galen L.
• Application Number:
  US08/610,230
• Time in Patent Office: 925 Days
• Field of Search: 244/117 A, 244/117 R, 244/133, 244/119, 244/121, 428/911, 428/212, 428/113, 428/240, 428/323, 428/902, 89/36.02, 89/36.11, 89/36.12
• US Class Current: 244/117.00R
• CPC Class Codes: B29C 44/1233 the preformed parts being supported during expanding
• CPC Class Codes: B29C 70/088 and with one or more layers of non-plastics material or non-specified material, e.g. supports
• CPC Class Codes: B29K 2105/16 Fillers
• CPC Class Codes: B29K 2705/00 Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
• CPC Class Codes: B29K 2995/0091 Damping, energy absorption
• CPC Class Codes: B29L 2007/002 Panels; Plates; Sheets
• CPC Class Codes: B32B 15/046 of foam
• CPC Class Codes: B32B 2266/06 Open cell foam
• CPC Class Codes: B32B 2605/18 Aircraft
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/14 applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: B64C 1/12 Construction or attachment of skin panels
• CPC Class Codes: B64C 2230/22 by using a surface having multiple apertures of relatively small openings other than slots
• CPC Class Codes: Y02T 50/10 Drag reduction
• CPC Class Codes: Y02T 50/40 Weight reduction
• CPC Class Codes: Y10S 428/911 Penetration resistant layer

Abstract

A composite laminate, an aircraft skin panel, an airfoil, an aircraft and a method of manufacturing such a composite laminate are provided. The laminate includes at least three layers, namely a first layer of fiber reinforced composite material, a second layer usually metallic and usually forming a surface of the component and a third layer of impact energy-absorbing material interposed between the first and second layers, wherein the second and third layers protect the first layer from impact damage. The method of manufacture involves placing all three layers, including a said third layer of foaming adhesive, in a closed mould and foaming the adhesive to form a component to shape.

Claims

1. A composite laminate including:

a first layer of fibre reinforced composite material, said first layer providing primary structural strength for said composite laminate;

a second layer forming a protective skin and having a property of plastic deformation under a substantial impact; and

a third layer of impact energy-absorbing material interposed between the first and second layers and having a property of energy absorption when deformed, said second and third layers not providing primary structural strength for said composite laminate, said second and third layers in combination providing both a visible indication of a substantial impact sufficient to deform said second layer of said composite material and protection to said first layer by energy absorption of said substantial impact in said third layer.

2. A composite laminate as in claim 1 in which the second layer is metallic.

3. A composite laminate as in claim 1 in which the second layer is of aluminium foil.

4. A composite laminate as in claim 1 in which the third layer comprises an in-situ foaming adhesive.

5. A composite laminate as in claim 1 in which the third layer comprises a micro-balloon filled resin.

6. A composite laminate as in claim 1 in which the third layer comprises a pre-foamed material.

7. A composite laminate as in claim 1 in which the third layer includes reinforcing fibres dispersed therein.

8. A composite laminate as in claim 7 in which the reinforcing fibres are woven together.

9. A composite laminate as in claim 7 in which the reinforcing fibres are predominantly positioned nearer to the second layer than the first layer.

10. A composite laminate as in claim 1 including a layer of damage sensor fibres positioned within the third layer adjacent the first layer.

11. A composite laminate as in claim 2 including at least one fluid passage defined through the third layer.

12. A composite laminate as in claim 11 in which the metallic layer is perforated to place the at least one fluid passage in the third layer in communication with the exterior of the laminate.

13. A composite laminate as in claim 12 in which the at least one fluid passage is defined through open cell foam of the third layer.

14. A composite laminate as in claim 13 in which the at least one fluid passage defined through the open cell foam is partly bounded by an impermeable layer placed at an intermediate position within the third layer.

15. A composite laminate as in claim 11 in which the at least one fluid passage is defined by channels formed between adjacent strips of adhesive of the third layer.

16. An aircraft skin panel comprising a composite laminate including:

a first layer of fibre reinforced composite material, said first layer providing primary structural strength for said composite laminate;

a metallic second layer and having a property of plastic deformation under a substantial impact; and

a third layer of impact energy-absorbing material interposed between the first and second layers and having a property of energy absorption when deformed, said second and third layers not providing primary structural strength for said composite laminate, said second and third layers in combination providing both a visible indication of a substantial impact sufficient to deform said second layer of said composite material and protection to said first layer by energy absorption of said substantial impact in said third layer.

17. An airfoil including at least one aircraft skin panel according to claim 16.

18. An aircraft fuselage including at least one skin panel according to claim 16.

19. An aircraft including at least one aircraft skin panel according to claim 16.

20. A method of manufacturing a composite laminate including a first layer of fibre reinforced composite material, a metallic second layer and a third layer of impact energy-absorbing material interposed between the first and second layers, the method including the steps of:

providing said pre-cured first layer of fibre reinforced composite material;

placing foaming adhesive on the first layer;

placing the second layer on the foaming adhesive to form a moulding assembly;

placing the moulding assembly in a mould of the required form, and

foaming the foaming adhesive where the expanding foam causes the second and third layers to form to the shape of the mould creating a composite laminate of the required form.