Abstract A technique for making a honeycomb structure includes bonding a less than totally cured composite skin (16) to a possibly contoured honeycomb core (8). The composite skin (16) comprises fibers and a resin chosen to maximize the strength and stiffness of the skin (16) when cured. Non- contiguous adhesive fillets (5) are prepositioned onto faying surfaces of the honeycomb core (8). The adhesive (5) is preselected, independently of the preselection of the resin, to maximize the strength of the bond between the skin (16) and the core (8). A thin, lightweight scrim cloth (14) is interposed between the starting skin (16) and the filleted core (8). The scrim cloth (14) prevents resin from flowing into the core (8) and allows a safe place for the intermingling of resin and adhesive (5). The assemblage is heated under pressure, cocuring the adhesive (5) and the resin. The fillets (5) are preferably prepositioned on surfaces (10) by means of applying an adhesive-coated fabric to the faying surface, heating the fabric-covered core (8) so that some of the adhesive (5) flows out of the fabric (1) and into the core (8) at a region near the faying surface, cooling the core (8) so that the only substance remaining adhered to the core edges (10) is the adhesive fillets (5).
A method of making a honeycomb structure by bonding a composite skin member onto a honeycomb core, characterised by the steps of: forming several non- contiguous fillets (5) of less than totally cured adhesive on a faying surface (10) of the core (12); placing a less than totally cured composite sheet (16) containing a resin against the faying surface (10); and heating the core (12) and composite sheet (16) to effect a final cure to each of the adhesive and the resin.
Claim 2
Independent Claim
82 words
A method of making a honeycomb structure by bonding a composite skin member onto a honeycomb core, characterised by the steps of: forming several non- contiguous fillets (5) of less than totally cured adhesive on a faying surface (10) of the core (12); placing a less than totally cured composite sheet (16) containing a resin against the faying surface (10); and heating the core (12) and composite sheet (16) to effect a final cure to each of the adhesive and the resin.
Claim 3
Dependent Claim
36 words
A method as claimed in claim 1, characterised in that, after the fillet forming step and before the heating step, a scrim cloth (14) is interposed between the faying surface (10) and the composite sheet (16).
Claim 4
Dependent Claim
63 words
A method as claimed in claim 1 or claim 2, characterised in that each composite sheet (16) comprises a fiber and a resin; the resin is preselected to optimize the strength of the skin (16) when cured; and the adhesive is preselected, independently of the preselection of the resin, to optimize the bonding strength between the cured skin (16) and the core (12).
Claim 5
Independent Claim
30 words
A method as claimed in any one of the preceding claims, characterised in that pressure is applied to the core (12) and the composite sheet (16) during the heating step.
Claim 6
Independent Claim
106 words
A method as claimed in any one of the preceding claims, characterised in that the step of forming adhesive fillets (5) is performed by following the substeps of applying an adhesive-coated fabric (1) against the faying surface (10); heating the adhesive-coated fabric covered honeycomb core (Figure 7) so that some of the adhesive flows out of the fabric (1) and into the core (12) at a region near the faying surface (10); cooling the core (10) so that the adhesive becomes brittle; and peeling the fabric (1) away from the core (10) so that the only substance remaining adhered to the core is the flowed adhesive.
Claim 7
Dependent Claim
14 words
A honeycomb structure made by the method of any one of the preceding claims.
References Cited (Backward Citations)
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