Large cell carbon core sandwich panel and method of manufacturing same

A method of fabricating a panel, comprising:

• placing a first laminate on a tooling surface, the first laminate having an outer surface and an inner surface;
• placing a first layer of thermoplastic on the inner surface of the first laminate;
• placing a core on the first layer of thermoplastic;
• placing a second layer of thermoplastic on the core;
• placing a second laminate on the second layer of thermoplastic, the second laminate having an outer surface and an inner surface, the inner surface facing the second layer of thermoplastic;
• bonding the first layer of thermoplastic to the second layer of thermoplastic surrounding a perimeter of the core, thereby creating a sealed core pocket;
• increasing pressure within the core pocket;
• increasing pressure on the outer surface of the second laminate;
• heating the first laminate, the second laminate, the first layer of thermoplastic, and the second layer of thermoplastic to a desired curing temperature;
• and
• maintaining the increased pressure within the core pocket, the pressure on the outer surface of the second laminate, and the curing temperature for a desired curing duration;
• and
• inserting a port in the second laminate, the port extending from the outer surface of the second laminate to the inner surface of the second laminate, and inserting a nozzle through the port into the core pocket;
• wherein the increasing the pressure within the core pocket comprises pumping a gas into the core pocket;
• and
• wherein the increasing the pressure on the outer surface of the second laminate comprises attaching a vacuum bag to the tooling surface around a perimeter of the second laminate and removing the gas from within the vacuum bag.