US 11,840,052 B2
Method for producing a composite component
Jürgen Langediers, Syke (DE); Berend Schoke, Twistringen (DE); and Marcel Meyer, Stuhr (DE)
Assigned to Airbus Operations GmbH, Hamburg (DE)
Filed by Airbus Operations GmbH, Hamburg (DE)
Filed on Jan. 26, 2022, as Appl. No. 17/585,041.
Application 17/585,041 is a continuation of application No. PCT/EP2020/070327, filed on Jul. 17, 2020.
Claims priority of application No. 10 2019 120 548.4 (DE), filed on Jul. 30, 2019.
Prior Publication US 2022/0203665 A1, Jun. 30, 2022
Int. Cl. B32B 37/24 (2006.01); B32B 3/12 (2006.01); B32B 37/02 (2006.01); B32B 37/06 (2006.01); B32B 37/14 (2006.01); B32B 38/00 (2006.01); B32B 38/16 (2006.01); B32B 38/08 (2006.01)
CPC B32B 37/24 (2013.01) [B32B 3/12 (2013.01); B32B 37/02 (2013.01); B32B 37/06 (2013.01); B32B 37/146 (2013.01); B32B 38/0036 (2013.01); B32B 38/162 (2013.01); B32B 38/08 (2013.01); B32B 2038/0076 (2013.01); B32B 2038/0088 (2013.01); B32B 2250/03 (2013.01); B32B 2250/40 (2013.01); B32B 2264/203 (2020.08); B32B 2305/024 (2013.01); B32B 2305/30 (2013.01); B32B 2305/72 (2013.01); B32B 2309/02 (2013.01); B32B 2309/72 (2013.01); B32B 2605/18 (2013.01)] 17 Claims
OG exemplary drawing
 
1. A method for producing a composite component which comprises a base layer, a cover layer and a honeycomb structure disposed between the base layer and the cover layer, the method comprising:
applying the honeycomb structure to the base layer to form a multiplicity of honeycomb chambers, which are open on a side pointing away from the base layer;
filling honeycomb chambers in a reinforcement region with granules during a filling procedure, wherein the granules, at a processing temperature at which the filling is carried out, do not adhere to the honeycomb structure, the base layer, or one another;
removing, when an actual filling level of one or more of the honeycomb chambers exceeds a granule filling level, a portion of the granules from the one or more honeycomb chambers such that, after the one or more honeycomb chambers have been filled with the granules and the portion of the granules have been removed, each of the honeycomb chambers in the reinforcement region is filled with the granules up to the granule filling level and honeycomb chambers outside of the reinforcement region are free of the granules;
applying the cover layer to the honeycomb structure such that the honeycomb chambers are closed;
heating the composite component to a first process temperature, at which the granules with which the honeycomb chambers are filled expand within the honeycomb chambers to form expanded granules; and
subsequently, heating the composite component to a second process temperature, at which the cover layer, the base layer, the honeycomb structure, and the expanded granules cure;
wherein a density of the expanded granules in the honeycomb chambers depends on the granule filling level;
wherein a portion of the granules is removed and granules of the portion of the granules removed from the honeycomb chambers are re-used for filling other honeycomb chambers; and
wherein the granules of the portion of the granules removed from the honeycomb chambers are cleaned prior to being re-used.