Patent ID: 7938922

Claim:
A method for bonding an uncured face sheet to a honeycomb, said method comprising the steps of: providing an uncured face sheet comprising an interior surface for bonding to said honeycomb and an exterior surface, said uncured face sheet comprising at least one fiber layer and an uncured thermosetting resin matrix; providing a honeycomb having walls that define a plurality of honeycomb cells wherein said walls have an edge for bonding to the interior surface of said uncured face sheet; coating the edge of said honeycomb walls with a thermoplastic adhesive that comprises polyamide to form an edge-coated honeycomb; applying said uncured face sheet to said edge-coated honeycomb so that said uncured thermosetting resin matrix contacts said coating of thermoplastic adhesive; heating said uncured face sheet and edge-coated honeycomb to a temperature that is sufficient to provide mixing of said thermoplastic adhesive with said uncured thermosetting resin matrix to form fillets comprising said thermoplastic adhesive and uncured thermosetting resin matrix; and maintaining said uncured face sheet and edge-coated honeycomb at a sufficient temperature to cure the uncured thermosetting resin matrix remaining in said uncured face sheet and said fillets to thereby bond said uncured face sheet to said honeycomb.