Method of sealing core material

Abstract

A molded composite structure and a method of manufacturing a molded composite structure are disclosed. In one embodiment, an aircraft wing panel and a method for manufacturing an aircraft wing panel are disclosed. In another embodiment, the method of manufacturing a molded composite structure uses a resin transfer molding process.

1 - 100 . (canceled)  
     
     
         101 . A method of sealing a core to be used in forming a composite structure, the method comprising: 
 applying a first thermoplastic barrier film to a first layer of supporting material;    applying an adhesive on a surface of the core to form a first adhesive layer on the core;    applying the first thermoplastic barrier film and first layer of supporting material on the core such that the first adhesive layer is against the first stabilizing material and the first layer of supporting material provides a vacuum path for evacuation of the core;    evacuating air from the core through the vacuum path provided by the first layer of supporting material;    curing the first adhesive layer to seal the portion of the core covered by the first thermoplastic barrier layer;    machining the core to a desired shape;    applying a second thermoplastic barrier film to a second layer of supporting material;    applying an adhesive on all unsealed surfaces of the core to form a second adhesive layer on the unsealed surfaces of the core;    applying the second thermoplastic barrier film and second layer of supporting material on the core such that the second adhesive layer is against the second layer of supporting material and the second layer of supporting material provides a vacuum path for evacuation of the core;    evacuating air from the core through the vacuum path provided by the second layer of supporting material; and    curing the second adhesive layer to form a sealed core.    
     
     
         102 . The method of  claim 101 , wherein the first and second layers of adhesive are roll-coated adhesives.  
     
     
         103 . The method of  claim 102 , wherein the first and second layers of roll-coated adhesive include an epoxy resin.  
     
     
         104 . The method of  claim 101 , wherein the first and second layers of supporting material include fibrous material.  
     
     
         105 . The method of  claim 101 , wherein the first and second layers of supporting material include a ply of composite skin material.  
     
     
         106 . The method of  claim 105 , wherein the composite skin material is impregnated with resin.  
     
     
         107 . The method of  claim 105 , wherein the composite skin material includes carbon fiber impregnated with an epoxy resin.  
     
     
         108 . The method of  claim 107 , wherein the carbon fiber has been wound so that substantially no gaps exist between adjacent bands of fibers.  
     
     
         109 . The method of  claim 101 , wherein the first and second thermoplastic barrier films include a polyetherimide thermoplastic barrier film.  
     
     
         110 . The method of  claim 101 , wherein the first and second thermoplastic barrier films include a polyvinyl fluoride film.  
     
     
         111 . A method of stabilizing and sealing a core to be used in forming a composite structure comprising: 
 machining the core to a desired shape;    applying a thermoplastic barrier film to a layer of supporting material;    applying an adhesive on all surfaces of the core to form an adhesive layer on the core;    applying the thermoplastic barrier film and first layer of supporting material on the core such that the adhesive layer is against the first layer of supporting material, the thermoplastic barrier film covers all surfaces of the core, and the layer of supporting material provides a vacuum path for evacuation of the core;    evacuating air from the core through the vacuum path provided by the first layer of supporting material; and    curing the adhesive layer to form a sealed core.    
     
     
         112 . The method of  claim 111 , wherein the layer of adhesive is a roll-coated adhesive.  
     
     
         113 . The method of  claim 112 , wherein the layer of roll-coated adhesive includes an epoxy resin.  
     
     
         114 . The method of  claim 111 , wherein the layer of supporting material includes a fibrous material.  
     
     
         115 . The method of  claim 111 , wherein the layer of supporting material includes a ply of composite skin material.  
     
     
         116 . The method of  claim 115 , wherein the composite skin material is impregnated with resin.  
     
     
         117 . The method of  claim 115 , wherein the composite skin material includes carbon fiber impregnated with an epoxy resin.  
     
     
         118 . The method of  claim 117 , wherein the carbon fiber has been wound so that substantially no gaps exist between adjacent bands of fibers.  
     
     
         119 . The method of  claim 111 , wherein the thermoplastic barrier film includes polyetherimide thermoplastic barrier film.  
     
     
         120 . The method of  claim 111 , wherein thermoplastic barrier film includes a polyvinyl fluoride film.  
     
     
         121 . A sealed core for use in forming a composite structure, said core comprising: 
 a core substantially evacuated of air;    a layer of adhesive on all surfaces of the core;    a layer of supporting material on the adhesive layer; and    a layer of thermoplastic barrier film on the stabilizing material and covering all surfaces of the core.    
     
     
         122 . The sealed core of  claim 121 , wherein layer of adhesive is a roll-coated adhesive.  
     
     
         123 . The sealed core of  claim 121 , wherein the layer of roll-coated adhesive includes an epoxy resin.  
     
     
         124 . The sealed core of  claim 121 , wherein the layer of supporting material includes fibrous material.  
     
     
         125 . The sealed core of  claim 121 , wherein the layer of supporting material includes a ply of composite skin material.  
     
     
         126 . The sealed core of  claim 125 , wherein the composite skin material is impregnated with resin.  
     
     
         127 . The sealed core of  claim 125 , wherein the composite skin material includes carbon fiber impregnated with an epoxy resin.  
     
     
         128 . The sealed core of  claim 127 , wherein the carbon fiber has been wound so that substantially no gaps exist between adjacent bands of fibers.  
     
     
         129 . The sealed core of  claim 121 , wherein the thermoplastic barrier film includes polyetherimide thermoplastic barrier film.  
     
     
         130 . The sealed core of  claim 121 , wherein thermoplastic barrier film includes a polyvinyl fluoride film.