Composite structures having reinforced edge bonded joints and method for making the same

Abstract

A ceramic matrix composite structure has a reinforced core for carrying loads. The core includes a web connected between the facesheets by edge bonded joints for transmitting compressive, tensile and shear loads. The edge bonded joints are laterally reinforced by bridging members bonded to the facesheets, on opposite sides of the webs. The bridging members may comprise low density, high temperature rigid foam.

1 . A method of forming a ceramic matrix composite structure, comprising the steps of:
 (A) forming first and second layers of bridging material;   (B) forcing a first edge of a web through the first layer of bridging material;   (C) forcing a second opposite edge of the web through the second layer of bridging material;   (D) applying first and second facesheets to opposite sides of the web; and   (E) bonding the first and second edges respectively to the first and second facesheets.   
     
     
         2 . The method of  claim 1 , further comprising the step of:
 (F) bonding the first and second layers of bridging material respectively to the first and second facesheets.   
     
     
         3 . The method of  claim 1 , wherein step (E) includes bonding the first and second layers of bridging material to the first and second facesheets substantially concurrently. 
     
     
         4 . The method of  claim 1 , further comprising the step of:
 (F) curing the ceramic matrix composite structure after step (E) has been completed.   
     
     
         5 . The method of  claim 1 , further comprising the step of:
 (F) manufacturing aircraft subassemblies using the ceramic composite matrix composite structure.   
     
     
         6 . A method of forming a ceramic matrix composite structure, comprising the steps of:
 (A) forming first and second layers of bridging material;   (B) forcing a first edge of a web through the first layer of bridging material;   (C) forcing a second opposite edge of the web through the second layer of bridging material;   (D) applying first and second facesheets to opposite sides of the web; and   (E) bonding the first and second edges respectively to the first and second facesheets.   
     
     
         7 . The method of  claim 6 , wherein steps (A) and (B) each include depositing rigid foam on the corresponding facesheet. 
     
     
         8 . The method of  claim 6 , further comprising the step of:
 (F) curing the structure after steps (A) through (E) have been performed.   
     
     
         9 . The method of  claim 6 , further comprising the step of:
 (F) filling space between the first and second layers of reinforcement material with a rigid foam.   
     
     
         10 . A method of forming a ceramic composite sandwich structure, comprising the steps of:
 (A) placing reinforcing core in a layer of foam;   (B) forming a first layer of bridging material on a first side of the foam layer bridging the sides of the core;   (C) bonding a first facesheet to the first side of the foam layer;   (D) forming a second layer of bridging material on a second side of the foam layer bridging the sides of the core;   (E) bonding a second facesheet to a second side of the foam layer.   
     
     
         11 . The method of  claim 10 , further comprising the step of:
 (F) curing the ceramic composite sandwich structure.   
     
     
         12 . The method of  claim 10 , wherein steps (B) and (D) each include forcing the core through a layer of the bridging material. 
     
     
         13 . The method of  claim 10 , further comprising the step of:
 (F) performing aircraft maintenance using the ceramic composite sandwich structure.   
     
     
         14 . A method of forming a ceramic composite sandwich structure, comprising the steps of:
 (A) forming structural stiffeners;   (B) forming bridging members for laterally reinforcing the stiffeners;   (C) forcing the stiffeners through the bridging members;   (D) laying up a facesheet; and,   (E) bonding the facesheet to the combination of the stiffeners and the bridging members.   
     
     
         15 . The method of  claim 14 , further comprising the step of:
 (F) removing a portion of the bridging members after step (E) has been performed   
     
     
         16 . The method of  claim 14 , further comprising the step of:
 (F) specifying materials used in the ceramic composite sandwich structure.   
     
     
         17 . The method of  claim 14 , further comprising the step of:
 (F) curing the ceramic composite sandwich structure.   
     
     
         18 . The method of  claim 14 , further comprising the step of:
 (F) manufacturing aircraft subassemblies using the ceramic composite sandwich structure.