Hybrid fiberglass composite structures and methods of forming the same

• US 7,740,932 B2
• Filed: 03/31/2005
• Issued: 06/22/2010
• Est. Priority Date: 03/31/2005
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Kismarton, Max U.
• Primary Examiner(s): Tarazano; D. Lawrence
• Assistant Examiner(s): Thompson; Camie S
• Application Number:
  US11/096,796
• Publication Number:
  US 20060219845A1
• Time in Patent Office: 1,909 Days
• Field of Search: 428/292.1, 428/297.1, 428/297.7, 428/299.4, 428/300.7, 428/411.1, 233/144
• US Class Current: 428/292.1
• 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 a second laminate substrate, wherein each laminate substrate includes at least one planar layer of glass fibers and a plurality of planar layers of polymer fibers; and

a cellular core structure interposed between the first laminate substrate and the second laminate substrate and coupled to the layers of polymer fibers in the laminate substrates.

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 the polymer fibers include one of polyethylene and polyurethane fibers.

5. The fiberglass composite structure of claim 1, wherein the polymer fibers include liquid crystalline polymer fibers.

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 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 equal proportions.

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

9. The structure of claim 1, wherein the structure is a leading or trailing edge of a wing, and wherein the glass fiber layers form outer layers and the polymer fiber layers form inner layers.

10. An aerospace vehicle, comprising:

a fuselage; and

wing assemblies and an empennage operatively coupled to the fuselage;

wherein leading edges of the wing assemblies are formed by composite structures, each 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 fixedly coupled to the first laminate substrate and the second laminate substrate.

11. The aerospace vehicle of claim 10, wherein at least one of the polymer fiber layers includes a polyethylene fiber layer or a liquid crystalline polymer fiber layer.

12. An aircraft structure comprising a contoured panel forming a leading or trailing edge of the structure, the panel including a honeycomb core sandwiched between first and second laminate substrates, each laminate substrate including a plurality of layers of glass fibers and a plurality of layers of polymer fibers, the polymer fiber layers between the core and the glass fiber layers.

13. The structure of claim 12, wherein the structure is a wing.

14. The structure of claim 12, wherein the polymer fibers include at least one of polyethylene and polyurethane fibers.

15. The structure of claim 12, wherein the polymer fibers include liquid crystalline polymer fibers.