IP Library › Granted Patent US 12,275,525
Granted Patent B2
US 12,275,525 · App. 17/252,710 · Granted Apr 15, 2025

Net edge composite core splices for aircraft wing

Inventors: James Donn Hethcock, Jr. (Colleyville, TX); Raymond Lester Humphries (Colleyville, TX); Matthew Barclay (Colleyville, TX)
Assignee: SIERRA NEVADA CORPORATION
B64C3/20B29C66/72525B29C70/68B32B3/12B32B3/28B32B5/142B32B7/02B32B7/12B29C70/32B29L2031/3085B32B2250/40B32B2260/021B32B2260/046B32B2307/724B32B2307/726B32B2307/7375B32B2605/18
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Quick Facts
Patent No.
US 12,275,525
App. No.
17/252,710
Granted
Apr 15, 2025
Kind
B2
Abstract

Methods and related structures to splice two sizes of cores in a manner to directly interface the facets of the cells and avoid the common practice of using fillers, casting materials, and expanding adhesives is useful to optimize the specific strength of the design and minimize the weight while maximizing the load carrying capability of the structure and to allow the core to vent moisture and other gasses.

Claims (10)

1. A method of assembling a core structure assembly, the method comprising:

providing a first composite core structure having a first plurality of cells and a first cell size, and a second composite core structure having a second plurality of cells and a second cell size, the second cell size being greater than the first cell size, wherein the first plurality of cells and the second plurality of cells each have a hexagonal cross-sectional shape and a centerline, wherein the first and second composite core structures are formed from a plurality of interconnected ribbons of composite material, wherein the plurality of interconnected ribbons are arranged in a length direction and a width direction;

arranging facets of some of the first plurality of cells in alignment with facets of some of the second plurality of cells to create facet interfaces that maximize surface contact between the first and second composite core structures, wherein an interconnected ribbon of composite material of the plurality of interconnected ribbons of composite material forms an end facet of the second plurality of cells and has a modified shape such that a plurality of cells of the second plurality of cells have additional end facets that maximize surface contact between the first and second composite core structures and do not have the hexagonal cross-sectional shape; and

connecting the first and second composite core structures together at the facet interfaces.

2. The method of claim 1 , wherein connecting the first and second composite core structures together includes bonding with an adhesive.

3. The method of claim 1 , wherein connecting the first and second composite core structures together includes creating a connection by cross-linking polymer materials and curing the first and second composite core structures.

4. The method of claim 3 , further comprising forming the first and second composite core structures by wrapping separate mandrels with composite materials and positioning the wrapped mandrels in contact with each other.

5. The method of claim 1 , further comprising forming at least one of the first and second composite core structures by connecting together a plurality of ribbon corrugations of composite material.

6. The method of claim 1 , further comprising preparing the facets for bonding by removing mold release chemicals from the facets.

7. The method of claim 1 , further comprising arranging facets of at least some of the first plurality of cells in alignment with facets of at least some of the second plurality of cells to create facet interfaces that provide surface contact and allow gas permeability between the first and second composite core structures.

Assignments (3)
CHANGE OF NAME Recorded Jan 9, 2025
From: SIERRA NEVADA CORPORATION
To: SIERRA NEVADA COMPANY, LLC
Reel/Frame 069807/0365 →
SECURITY INTEREST Recorded Jun 30, 2023
From: SIERRA NEVADA CORPORATION
To: BANK OF AMERICA, N.A., AS ADMINISTRATIVE AGENT
Reel/Frame 064179/0058 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 16, 2021
From: HETHCOCK, JAMES DONN, JR.; HUMPHRIES, RAYMOND LESTER; BARCLAY, MATTHEW
To: SIERRA NEVADA CORPORATION
Reel/Frame 055610/0168 →
Continuity (2)
Provisional Application 62688080 · Jun 21, 2018
Related Publication 20210155337A1 · May 27, 2021
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