Patent US1745916A successfully refreshed from Google Patents.
US5049342A
Expired / Lapsed
US
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Method of fabricating composite structures
Assignee: Sundstrand Corp
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Filing: 1990-05-09
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Granted: 1991-09-17
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Expires: 2010-05-09
Abstract
Abstract A method of fabricating a composite structure having at least one skin molecularly bonded to a core. A skin is provided of reinforcing fibrous material and a thermoplastic matrix. The skin is thermoformed to the general exterior shape of the composite structure. A core having a thermoplastic matrix complementary to the matrix of the skin is molded into the general shape of the composite structure. The skin and the core are placed in juxtaposition in a final forming mold. A thermoplastic material is injected into the final forming mold under isostatic conditions. The thermoplastic material is complementary to the thermoplastic matrices of the skin and the core.
Inventors
- 👤 John F. Scanlon
- 👤 Hossein Saatchi
- 👤 David W. Okey
- 👤 John S. Church
- 👤 Gary A. Wigell
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 17:46
CPC Classifications
B; B29; B29C; B29C65/00; B29C65/02; B29C65/40; B29C65/42; B29C45/00; B29C45/14; B29C45/14467; B29C66/00; B29C66/70; B29C66/71; B29C66/72; B29C66/721; B29C66/73; B29C66/739; B29C66/7392; B29C66/73921; B29C66/7212; B29C66/7214; B29C66/72141; B29C66/72143; B29K; B29K2071/00; B29K2105/00; B29K2105/04; B29K2105/06; B29K2105/08; B29K2105/0809; B29K2105/0854; B29K2105/12; B29K2105/16
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
131 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core in a separate step independent of and separate from the thermoforming of the skin, into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the independently thermoformed skin and the independently molded core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 2
Independent Claim
131 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core in a separate step independent of and separate from the thermoforming of the skin, into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the independently thermoformed skin and the independently molded core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 3
Independent Claim
23 words
The method of claim wherein the reinforcing material of said skin is selected from the group consisting of graphite, glass, aramid and ceramic.
Claim 4
Dependent Claim
15 words
The method of claim 1 wherein said core matrix includes a filler material of microspheres.
Claim 5
Dependent Claim
15 words
The method of claim 1 wherein the reinforcing material of said skin is woven fibers.
Claim 6
Dependent Claim
15 words
The method of claim 1 wherein the reinforcing material of said skin is braided fibers.
Claim 7
Dependent Claim
15 words
The method of claim 1 wherein the reinforcing material of said skin is chopped fibers.
Claim 8
Independent Claim
135 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of fibrous reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core in a separate step independent of and separate from the thermoforming of the skin, into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the independently thermoformed skin and the independently molded core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under conditions of pressure and heat, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 9
Independent Claim
135 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of fibrous reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core in a separate step independent of and separate from the thermoforming of the skin, into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the independently thermoformed skin and the independently molded core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under conditions of pressure and heat, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 10
Dependent Claim
15 words
The method of claim 7 wherein the reinforcing material of said skin is graphite fibers.
Claim 11
Dependent Claim
15 words
The method of claim 7 wherein said core matrix includes a filler material of microspheres.
Claim 12
Dependent Claim
15 words
The method of claim 7 wherein the reinforcing material of said skin is woven fibers.
Claim 13
Dependent Claim
15 words
The method of claim 7 wherein the reinforcing material of said skin is braided fibers.
Claim 14
Independent Claim
132 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing fibrous material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core in a separate step independent of and separate from the thermoforming of the skin, into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the independently thermoformed skin and the independently molded core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 15
Independent Claim
132 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing fibrous material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core in a separate step independent of and separate from the thermoforming of the skin, into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the independently thermoformed skin and the independently molded core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 16
Independent Claim
113 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a polyetheretherketone matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 17
Independent Claim
113 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a polyetheretherketone matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 18
Independent Claim
113 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a polyetheretherketone matrix complementary to the matrix of the skin; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 19
Independent Claim
113 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a polyetheretherketone matrix complementary to the matrix of the skin; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 20
Independent Claim
115 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a liquid crystal polymer matrix complementary to the matrix of the skin; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 21
Independent Claim
115 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a liquid crystal polymer matrix complementary to the matrix of the skin; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a thermoplastic material into the mold under isostatic conditions, the thermoplastic material being complementary to the thermoplastic matrices of the skin and the core.
Claim 22
Independent Claim
113 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a polyetheretherketone material into the mold under isostatic conditions, the polyetheretherketone material being complementary to the thermoplastic matrices of the skin and the core.
Claim 23
Independent Claim
113 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of reinforcing material and a thermoplastic matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a thermoplastic matrix complementary to the matrix of the skin; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a polyetheretherketone material into the mold under isostatic conditions, the polyetheretherketone material being complementary to the thermoplastic matrices of the skin and the core.
Claim 24
Independent Claim
95 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of fibrous reinforcing material and a polyetheretherketone matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a polyetheretherketone matrix; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a polyetheretherketone material into the mold under conditions of pressure and heat.
Claim 25
Independent Claim
95 words
A method of fabricating a composite structure having at least one skin molecularly bonded to a core, comprising the steps of: providing a skin composed of fibrous reinforcing material and a polyetheretherketone matrix; thermoforming the skin to the general exterior shape of the composite structure; molding a core into the general shape of the composite structure, the core having a polyetheretherketone matrix; and final forming the composite structure by placing the skin and the core in juxtaposition in a forming mold and injecting a polyetheretherketone material into the mold under conditions of pressure and heat.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-09-16 | 1995-03-18 | 1995-09-17 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-09-16 | 1999-03-18 | 1999-09-17 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-09-16 | 2003-03-18 | 2003-09-17 | $7700.00 | Window Closed / Lapsed |