Composite panel and method of manufacturing the same

Abstract

A method of manufacturing a composite panel is described. The method includes pre-stabilizing a honeycomb core with at least one layer of a pre-stabilizing material, surrounding the honeycomb core with at least one composite laminate skin layer, and curing the at least one composite laminate skin layer.

1 . A method of manufacturing a composite panel, said method comprising:
 pre-stabilizing a honeycomb core with at least one layer of a pre-stabilizing material;   surrounding said honeycomb core with at least one composite laminate skin layer; and   curing said at least one composite laminate skin layer.   
   
   
       2 . A method according to  claim 1  wherein pre-stabilizing said honeycomb core comprises applying at least one layer of pre-stabilizing material to said honeycomb core, such that said at least one layer of pre-stabilizing material substantially surrounds said honeycomb core. 
   
   
       3 . A method according to  claim 2  further comprising coupling said at least one layer of pre-stabilizing material to said honeycomb core using an adhesive. 
   
   
       4 . A method according to  claim 2  wherein applying at least one layer of pre-stabilizing material comprises applying at least one layer of composite material. 
   
   
       5 . A method according to  claim 4  wherein said composite material comprises at least one layer of a fiberglass fabric. 
   
   
       6 . A method according to  claim 1  further comprising machining said honeycomb core to a desired shape and size. 
   
   
       7 . A method according to  claim 1  wherein pre-stabilizing comprises curing said pre-stabilizing material by applying heat and pressure. 
   
   
       8 . A method according to  claim 7  wherein pre-stabilizing said honeycomb core further comprises forming said honeycomb core into a desired shape while curing said pre-stabilizing material. 
   
   
       9 . A method according to  claim 1  wherein surrounding said honeycomb core with at least one composite laminate skin layer comprises positioning said honeycomb core adjacent to a first composite skin and positioning a second composite skin adjacent to an opposite side of said honeycomb core. 
   
   
       10 . A method according to  claim 1  wherein surrounding said honeycomb core with at least one composite laminate skin layer comprises positioning said honeycomb core adjacent to a first composite skin and folding said first composite skin over said honeycomb core, 
   
   
       11 . A method according to  claim 1  wherein curing said at least one composite laminate skin comprises heating said at least one composite laminate skin layer while applying a pressure that is higher than a pressure that can be applied to composite panels that do not include a pre-stabilized honeycomb core. 
   
   
       12 . A method according to  claim 11  wherein said higher pressure is at least fifty pounds per square inch (psi). 
   
   
       13 . A composite panel comprising:
 a pre-stabilized honeycomb core surrounded by a pre-stabilizing material; and   at least one laminate skin positioned to surround said pre-stabilized honeycomb core.   
   
   
       14 . A composite panel according to  claim 13  wherein said honeycomb core is pre-stabilized by applying a composite material to said honeycomb core and curing said composite material. 
   
   
       15 . A composite panel according to  claim 13  wherein said pre-stabilizing material is coupled to said honeycomb core using an adhesive. 
   
   
       16 . A composite panel according to  claim 13  wherein said at least one laminate skin is coupled to said pre-stabilized honeycomb core using an adhesive. 
   
   
       17 . A composite panel according to  claim 13  wherein said laminate skin comprises at least one composite material. 
   
   
       18 . A composite panel according to  claim 13  wherein said at least one composite material skin is substantially non-porous. 
   
   
       19 . A composite panel according to  claim 13  wherein said composite panel is able to be inspected with at least one non-destructive inspection method to quantify porosity. 
   
   
       20 . A composite panel according to  claim 18  wherein said at least one non-destructive inspection method comprises ultrasonic testing.