Patent ID: 8017054
Filing Date: 2011-09-13
Classification: B29C,B29L,Y10T

Abstract:
1. A method of fabricating a composite article comprising the steps of: providing a plurality of support templates; arranging the support templates to define a shape of the composite article; providing a plurality of primary panels, where providing a plurality of secondary panels, where each secondary panel defines at least one edge, a first surface, and a second surface; providing a plurality of tertiary panels, where each tertiary panel defines at least one edge, a first surface, and a second surface; bending the at least one flat primary panel such that the first and second surfaces thereof are no longer substantially planar; securing the first surface of the plurality of primary panels to the plurality of templates such that forming an inner skin by joining the adjacent edge portions of adjacent primary panels; after the inner skin has been formed, arranging the plurality of secondary panels such that joining the second surfaces of at least some of the primary panels to the first surfaces of at least some of the secondary panels adjacent thereto; forming a core by joining the adjacent edge portions of the secondary panels; after the core has been formed, arranging the plurality of tertiary panels such that joining the second surfaces of at least some of the secondary panels to the first surfaces of the tertiary panels adjacent thereto; forming an outer skin having exposed edge junctures by joining the adjacent edge portions of the tertiary panels; finishing the outer skin of the composite article by finishing the exposed edge junctures of the tertiary panels; and removing the plurality of support templates from the plurality of panels.