Patent ID: 7294220

Claim:
A method of stabilizing and sealing a core to be used in a composite structure comprising: applying a first thermoplastic barrier film to a first stabilizing material; rolling a first layer of roll-coated adhesive on a top surface of the core and a bottom surface opposing that top surface to form a first roll-coated adhesive layer on the core; applying the first thermoplastic barrier film and first stabilizing material on the core such that the first roll-coated adhesive layer is against the first stabilizing material and the first thermoplastic barrier film covers the top and bottom surfaces of the core; curing the first stabilizing material to form a core with stabilized top and bottom surfaces; machining the core to a desired shape; applying a second thermoplastic barrier film to a second stabilizing material; rolling a second layer of roll-coated adhesive on all machined surfaces of the core to form a second roll-coated adhesive layer on the machined surfaces of the core; applying the second thermoplastic barrier film and second stabilizing material on the core such that the second roll-coated adhesive layer is against the second stabilizing material and the thermoplastic barrier film covers the machined surfaces of the core; and curing the second stabilizing material to form a stabilized and sealed core.