Composite Panel Sandwich Structures with Integrated Joints

Abstract

A method and apparatus for fabricating a composite structure. The method comprises defining a shape for the composite structure with a first face sheet. The method places core sections on the shape defined by the first face sheet. The method places an adhesive in a group of joint cavities. The method places a second face sheet on the core sections placed on the first face sheet, wherein the first face sheet, the core sections, and the second face sheet, define a structural assembly in which the group of joint cavities are present. The method cures the structural assembly with the adhesive in the group of joint cavities to fabricate the composite structure in which the adhesive fills the group of joint cavities when the adhesive is cured.

What is claimed is: 
     
         1 . A composite panel sandwich structure comprising:
 a first face sheet having a shape for the composite panel sandwich structure;   a second face sheet having the shape;   a plurality of core sections located between the first face sheet and the second face sheet in which the first face sheet, the second face sheet, and the plurality of core sections define a group of joint cavities; and   an adhesive located in the group of joint cavities in which the adhesive expands to fill each of the group of joint cavities when the adhesive is cured.   
     
     
         2 . The composite panel sandwich structure of  claim 1 , wherein the adhesive comprises at least one of a nonflowing adhesive that does not flow during curing, a foaming adhesive, or an expanding adhesive. 
     
     
         3 . The composite panel sandwich structure of  claim 1 , wherein the first face sheet is comprised of a first group of plies and the second face sheet is comprised of a second group of plies. 
     
     
         4 . The composite panel sandwich structure of  claim 3 , wherein a first ply in the first group of plies comprises at least one of a carbon fiber reinforced polymer, a carbon fiber reinforced thermoplastic polymer, a carbon fiber reinforced thermoset polymer, a glass fiber reinforced thermoplastic polymer, or a glass fiber reinforced thermoset polymer, wherein a second ply in the second group of plies comprises at least one of the carbon fiber reinforced polymer, the carbon fiber reinforced thermoplastic polymer, the carbon fiber reinforced thermoset polymer, the glass fiber reinforced thermoplastic polymer, or the glass fiber reinforced thermoset polymer. 
     
     
         5 . The composite panel sandwich structure of  claim 1 , wherein the plurality of core sections comprise at least one of a honeycomb core, a closed cell foam core, or an open cell foam core. 
     
     
         6 . The composite panel sandwich structure of  claim 1 , wherein the composite panel sandwich structure is part of a composite structure selected from a group consisting of an aircraft structure, a control surface, a monument for an aircraft cabin, an overhead stowage bin, a closet, a lavatory, a galley, and a cabinet. 
     
     
         7 . The composite panel sandwich structure of  claim 1 , wherein the shape is a three-dimensional shape. 
     
     
         8 . An apparatus, comprising the composite panel sandwich structure of  claim 1 . 
     
     
         9 . A composite panel sandwich structure comprising:
 a first face sheet having a three-dimension shape for the composite panel sandwich structure in which the first face sheet is comprised of a first group of plies;   a second face sheet having the three-dimensional shape in which the second face sheet is comprised of a second group of plies, wherein a first ply in the first group of plies comprises at least one of a carbon fiber reinforced polymer, a carbon fiber reinforced thermoplastic polymer, a carbon fiber reinforced thermoset polymer, a glass fiber reinforced thermoplastic polymer, or a glass fiber reinforced thermoset polymer, wherein a second ply in the second group of plies comprises at least one of the carbon fiber reinforced polymer, the carbon fiber reinforced thermoplastic polymer, the carbon fiber reinforced thermoset polymer, the glass fiber reinforced thermoplastic polymer, or the glass fiber reinforced thermoset polymer;   a plurality of core sections located between the first face sheet and the second face sheet, wherein the first face sheet, the second face sheet, and the core sections define a group of joint cavities, wherein the plurality of core sections comprise at least one of a honeycomb core, a closed cell foam core, or an open cell foam core; and   an adhesive located in the group of joint cavities in which the adhesive comprises at least one of a nonflowing adhesive that does not flow during curing, a foaming adhesive, or an expanding adhesive, wherein the adhesive expands to fill each of the group of joint cavities when the adhesive is cured.   
     
     
         10 . The composite panel sandwich structure of  claim 9 , wherein the composite panel sandwich structure is part of a composite structure selected from a group consisting of an aircraft structure, a control surface, a monument for an aircraft cabin, an overhead stowage bin, a closet, a lavatory, a galley, and a cabinet. 
     
     
         11 . An apparatus, comprising the composite panel sandwich structure of  claim 9 . 
     
     
         12 . A composite structure, comprising:
 a first face sheet having a shape for the composite structure;   a second face sheet having the shape;   a plurality of core sections located between the first face sheet and the second face sheet, wherein the first face sheet, the second face sheet, and the plurality of core sections define a group of joint cavities, wherein each of the group of joint cavities is adjacent at least two of the plurality of core sections; and   an adhesive located in each of the group of joint cavities, wherein the adhesive fills each of the group of joint cavities and contacts both of the at least two of the plurality of core sections that are adjacent each of the group of joint cavities,   wherein the adhesive in each of the group of joint cavities only contacts edges of the at least two of the plurality of core sections and does not penetrate interiors of the at least two of the plurality of core sections.   
     
     
         13 . The composite structure of  claim 12 , wherein the adhesive comprises a plurality of layers of adhesive. 
     
     
         14 . The composite structure of  claim 12 , wherein the adhesive comprises at least one of a nonflowing adhesive that does not flow during curing, a foaming adhesive, or an expanding adhesive. 
     
     
         15 . The composite structure of  claim 12 , wherein the first face sheet comprises a first group of plies and the second face sheet comprise a second group of plies. 
     
     
         16 . The composite structure of  claim 15 , wherein a first ply in the first group of plies is comprised of at least one of a carbon fiber reinforced polymer, a carbon fiber reinforced thermoplastic polymer, a carbon fiber reinforced thermoset polymer, a glass fiber reinforced thermoplastic polymer, or a glass fiber reinforced thermoset polymer and a second ply in the second group of plies is comprised of at least one of the carbon fiber reinforced polymer, the carbon fiber reinforced thermoplastic polymer, the carbon fiber reinforced thermoset polymer, the glass fiber reinforced thermoplastic polymer, or the glass fiber reinforced thermoset polymer. 
     
     
         17 . The composite structure of  claim 12 , wherein the shape defines a three-dimensional shape having contours. 
     
     
         18 . The composite structure of  claim 12 , wherein the plurality of core sections comprise at least one of a honeycomb core, a closed cell foam core or an open cell foam core. 
     
     
         19 . The composite structure of  claim 12 , wherein the composite panel sandwich structure is part of a composite structure selected from a group consisting of an aircraft structure, a control surface, a monument for an aircraft cabin, an overhead stowage bin, a closet, a lavatory, a galley, and a cabinet. 
     
     
         20 . An apparatus, comprising the composite structure of  claim 12 .