Patent ID: 6375779
Filing Date: 2002-04-23
Classification: B32B,Y10T

Abstract:
A method of fabricating a three dimensional structural article having a desired configuration from a plurality of materials, each material having low radar reflectivity characteristics, said method comprising the steps of:providing a low density syntactic foam core; forming said foam core substantially into the desired configuration, said formed foam core having at least one exposed surface; providing an outer skin having a plurality of structural fibers intermixed with a resin matrix, said outer skin being configured to fit over and mate with the exposed surface of said formed foam core and having a dielectric constant of less than about 2.8; providing a syntactic foam sealing adhesive film adapted for sealing said exposed surface of said foam core and adhering with said outer skin, said syntactic foam sealing adhesive film having a dielectric constant of less than about 2.5 and said foam core having a dielectric constant which is less than that of said syntactic foam sealing adhesive film; supporting the formed foam core; placing a layer of the sealing adhesive film on the exposed surface of the formed foam core; placing the outer skin on the formed foam core such that the layer of sealing adhesive film is sandwiched between the outer skin and the exposed surface; and curing the structural article, such that the sealing adhesive film secures the outer skin to the foam core.