Highly ordered Z-pin structures

• US 5,869,165 A
• Filed: 11/10/1997
• Issued: 02/09/1999
• Est. Priority Date: 04/05/1996
• Status: Expired due to Term

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Falcone, Anthony, Rorabaugh, Michael E.
• Primary Examiner(s): Bell, James J.
• Assistant Examiner(s): Copenheaver, Blaine R.
• Application Number:
  US08/966,592
• Time in Patent Office: 456 Days
• Field of Search: 428/223, 428/86, 428/304.4, 428/105, 428/318.4, 428/109, 428/319.3, 428/119, 428/120, 442/370, 442/373
• US Class Current: 428/105
• CPC Class Codes: 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
• CPC Class Codes: B29C 70/24 oriented in at least three directions forming a three dimensional structure
• CPC Class Codes: B29K 2715/003 Cellular or porous
• CPC Class Codes: B32B 2266/02 Organic
• CPC Class Codes: B32B 2305/08 Reinforcements
• CPC Class Codes: B32B 2307/542 Shear strength
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 7/09 by stitching, needling or sewing by mechanically connecting fibrous layers to another layer B32B5/06
• CPC Class Codes: Y10T 29/49625 Openwork, e.g., a truss, joist, frame, lattice-type or box beam
• CPC Class Codes: Y10T 29/49833 Punching, piercing or reaming part by surface of second part
• CPC Class Codes: Y10T 428/23914 Interlaminar
• CPC Class Codes: Y10T 428/24058 including grain, strips, or filamentary elements in respective layers or components in angular relation
• CPC Class Codes: Y10T 428/24091 with additional layer[s]
• CPC Class Codes: Y10T 428/24174 including sheet or component perpendicular to plane of web or sheet
• CPC Class Codes: Y10T 428/24182 Inward from edge of web or sheet
• CPC Class Codes: Y10T 428/249923 Including interlaminar mechanical fastener
• CPC Class Codes: Y10T 428/249953 Composite having voids in a component [e.g., porous, cellular, etc.]
• CPC Class Codes: Y10T 428/249991 Synthetic resin or natural rubbers
• CPC Class Codes: Y10T 442/647 : Including a foamed layer or component
• CPC Class Codes: Y10T 442/651 : Plural fabric layers

Abstract

Improved pin-reinforced sandwich structure ties the face sheets (typically on opposite sides of a foam core) together with a plurality of Z-pins that extend into each face sheet (through the core). The pins are arranged in a tetrahedral or hat section configuration in 2-dimensional or 3-dimensional arrangements to provide enhanced reinforcement, particularly in shear. We are able to improve the pulloff strength additionally by dimpling the core surrounding the pins to produce adhesive fillets along the pins.

Claims

1. A pin-reinforced sandwich structure, comprising:

(a) a core having opposed first and second surfaces;

(b) a first face sheet adjacent the first surface and containing a resin;

(c) a second face sheet adjacent the second surface and containing a resin;

(d) a plurality of separate pins inserted into the first and second face sheets and extending through the core to form a pin-reinforced sandwich structure, and

(e) dimples in the core adjacent and surrounding each pin and adjacent each face sheet, each dimple being filled with resin from a face sheet to produce resin fillets for improved pulloff strength of the face sheets from the core

wherein the pins form an ordered configuration to enhance pulloff strength, the configuration being tetrahedral or hat section.

2. The structure of claim 1 wherein the face sheets are adhered to the core.

3. The structure of claim 1 wherein the core is organic matrix resin foam.

4. The structure of claim 1 wherein the face sheets are fiber-reinforced resin composites.

5. The structure of claim 1 wherein the pins are metal, graphite, glass, or carbon and have a Young'"'"'s modulus of at least about 10⁷.

6. A pin-reinforced sandwich structure, comprising:

(a) a first face sheet generally defining an X-Y plane;

(b) a second face sheet separated from the first face sheet by an unfilled gap between the face sheets; and

(c) a plurality of separate pins inserted into the first and second face sheets generally in a Z-direction to hold the face sheets apart and to form a pin-reinforced sandwich structure, wherein the pins are metal, graphite, glass, or carbon, have a Young'"'"'s modulus of at least about 10⁷, and form an ordered tetrahedral or hat section configuration skew to both the X-Z and Y-Z planes.

7. A pin-reinforced sandwich structure, comprising:

(a) a foam or foam-filled honeycomb core having opposed first and second surfaces;

(b) two face sheets, one face sheet adhered to each of the first and second surfaces, each face sheet including fiber-reinforced organic matrix ream;

(c) a plurality of separate pins at an areal density of about (0.375-1.50% inserted into the face sheets and extending through the core to provide improved pulloff strength of the face sheets from the core; and

(d) resin fillets of the same resin as the organic matrix resin of the face sheets around each pin and penetrating into the core at the face sheet-core interface.

8. A pin-reinforced sandwich structure, comprising:

(a) a core having opposed first and second surfaces, the core being foam, syntactic foam, a fiber-reinforced resin prepreg or composite, a fiberform or microform ceramic, a metal/foil hybrid laminate, or a foam-filled honeycomb;

(b) a fiber-reinforced resin matrix face sheet adhered to each of the first and second surfaces, the surfaces defining generally an X-Y plane;

(c) a plurality of separate stainless steel, titanium, copper, graphite, epoxy, composite, carbon, or glass pins at an areal density of about 0.375-1.50% inserted into the face sheets and extending through the core generally in a Z-direction normal to the X-Y plane;

the pins having a Young'"'"'s modulus of at least about 10⁷ ; and

(d) resin fillets extending into the core around each pin at the face sheet-core interface.

9. The sandwich structure of claim 8 wherein the pins are arranged in a tetrahedral array.

10. The sandwich structure of claim 8 wherein the pins are arranged in a hat section array.

11. The sandwich structure of claim 8 wherein the pins are skew to both the X-Z and Y-Z planes.

12. The sandwich structure of claim 11 wherein the pins are arranged in a hat section array.

13. The sandwich structure of claim 11 wherein the pins are arranged in a tetrahedral array.