Patent ID: 8834667
Filing Date: 2014-09-16
Classification: B29C,B29L,B32B,B64C,Y02T,Y10T

Abstract:
1. A method of fabricating a composite structure, comprising: forming first and second panels each having a fluted core and an end, the first and second panels each having a core sandwiched between first and second facesheets, the core comprising a support between the first and second facesheets, the fluted cores being mismatched at the first and second panel ends, creating mismatched cores, the first and the second panels each comprising a truss panel having a fluted core, the fluted core being a series of hollow isosceles trapezoidal flutes with inclined side walls extending traverse to a plane of the first and second face sheets; altering the first and second panel ends to match-up the mismatched cores, so as to form altered panel ends, the altering including removing at least a portion of the flutes between the first and second facesheets; installing a composite core stiffener insert between the altered panel ends, the composite core stiffener comprising a plurality of fibers that form a web and a set of flanges, the set of flanges adhered to the first panel and the second panel, the web comprising a substantially straight portion extending between the first panel and the second panel such that the set of flanges contact an inner surface of the first panel and an inner surface of the second panel; and joining the altered panel ends together at a joint.