Patent ID: 8052831
Filing Date: 2011-11-08
Classification: B29C,B29L,B32B,Y10T

Abstract:
1. A method for forming a honeycomb composite structure that comprises a skin and a honeycomb core having a plurality of cells, wherein the skin comprises at least one fibrous sheet and a polymer matrix and is cured or uncured, the method comprising: placing a scrim between the honeycomb core and the skin to allow flow of gasses and of the polymer matrix between cells of the honeycomb core during a vacuum forming portion of a bonding operation to bond the skin and the honeycomb core; forming the scrim with openings that are each smaller than each of said cells of the honeycomb core; perforating the skin with at least one vent sized to enable the gasses inside the honeycomb composite structure, and the polymer matrix, to be drawn through the vent during the vacuum forming portion of the bonding operation before the vent becomes sealed by the polymer matrix; further comprising placing a fibrous venting wick through the at least one vent before bonding the skin and the honeycomb core, wherein at least a portion of the fibrous venting wick is integrated into the skin during the bonding operation by the polymer matrix sealing the at least one vent; and bonding the skin and the honeycomb core during the bonding operation.