Patent ID: 8007628

Claim:
A method for creating a cellular composite structure, the structure including a grid structure having a plurality of intersecting ribs, selected segments of the intersecting ribs creating a plurality of contiguous walls each defining one of a plurality of cavities, the method comprising: shaping a cap member having at least first and second layers of resin pre-impregnated cloth abutting together to define an end wall that lays within, and defines a perimeter, that substantially matches an inner perimeter of one of the contiguous walls; orienting a first freely extending portion of the first cloth layer perpendicular to a remainder of the first cloth layer, and orienting a second freely extending portion of the second cloth layer perpendicular to a remainder of the second cloth layer, and further such that said first and second cloth layers overlap one another only within an area defined by the inner perimeter of one of the contiguous walls; positioning the cap member within one of the cavities having each of the first and second freely extending portions in contact with different portions of the contiguous wall; and co-curing the cap member and the grid structure to bond the first and second freely extending portion of each of the first and second cloth layers to the different portions of the contiguous wall to create the cellular composite structure.