US 11,673,366 B2
Reinforced sandwich panels using expandable foam materials and methods of making the same
Xiaoxi Wang, Mukilteo, WA (US); and Gary E. Georgeson, Tacoma, WA (US)
Assigned to THE BOEING COMPANY, Arlington, VA (US)
Filed by The Boeing Company, Chicago, IL (US)
Filed on Jul. 8, 2021, as Appl. No. 17/370,334.
Prior Publication US 2023/0011943 A1, Jan. 12, 2023
Int. Cl. B32B 5/18 (2006.01); B32B 7/12 (2006.01); B32B 15/04 (2006.01); B32B 18/00 (2006.01); B32B 27/06 (2006.01); B64C 1/12 (2006.01); B64D 45/02 (2006.01)
CPC B32B 5/18 (2013.01) [B32B 7/12 (2013.01); B32B 15/046 (2013.01); B32B 18/00 (2013.01); B32B 27/065 (2013.01); B32B 2250/40 (2013.01); B32B 2307/202 (2013.01); B32B 2307/302 (2013.01); B32B 2605/18 (2013.01); B64C 1/12 (2013.01); B64D 45/02 (2013.01)] 16 Claims
OG exemplary drawing
 
1. A reinforced sandwich panel, comprising:
two skin panels;
a foam core disposed between the two skin panels;
an expandable framework in an expanded state separating the two skin panels a predetermined distance and defining a fillable cavity in full fluid communication between the two skin panels; and
a flexible film, wherein the foam core is encapsulated by the flexible film, and wherein the flexible film bonds the foam core to at least one of the skin panels or the expandable framework,
wherein the encapsulated foam core is disposed within the fillable cavity and wherein the expandable framework acts as a skeleton for the encapsulated foam core,
wherein the encapsulated foam core fills substantially all of the fillable cavity, and
wherein the expandable framework is configured to resiliently expand from a collapsed state to the expanded state, and wherein the expandable framework is biased toward the expanded state such that reinforced sandwich panel expands to the expanded state solely due to a resilient force of the expandable framework, wherein the expandable framework comprises a plurality of interconnected and expandable struts configured to expand from the collapsed state to the expanded state, and wherein the plurality of interconnected and expandable struts are configured to lock in at least one of the collapsed state and the expanded state.