Method of integrally forming ribs in a composite panel

A method of integrally forming a composite panel with a composite rib structure comprising:

• positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, the fiber sheet including a plurality of fibers oriented along a first common direction;
• extending the wedge-shaped protrusion through the first fiber sheet such that a subset of the plurality of fibers is displaced about the protrusion and into each of the respective first channel and second channel;
• applying a resin within each of the respective first channel and second channel to the plurality of fibers;
• pre-curing the resin to form a pre-preg rib structure within the channels;
• and
• removing the pre-preg rib structure from the pre-preg mold;
• inserting the pre-preg rib structure into a part mold;
• overlaying the pre-preg rib structure with a composite pre-preg panel;
• and
• curing the pre-preg rib structure and the composite pre-preg panel within the part mold to fuse the pre-preg rib structure with the composite pre-preg panel.

A method of integrally forming a composite panel with a composite rib structure comprising:

• positioning a first fiber sheet on a pre-preg mold, the pre-preg mold including a first channel and a second channel separated by a wedge-shaped protrusion, the fiber sheet including a plurality of fibers oriented along a first common direction;
• positioning a second fiber sheet on the pre-preg mold prior to applying the resin, the second fiber sheet including a second plurality of fibers oriented along a second common direction, the pre-preg mold including a third channel and a fourth channel separated by the wedge-shaped protrusion and each disposed at an angle to the respective first channel and second channel;
• extending the wedge-shaped protrusion through each of the first fiber sheet and second fiber sheet such that a subset of the plurality of fibers is displaced about the protrusion and into each of the respective first channel, second channel, third channel, and fourth channel;
• applying a resin within each of the respective first channel, second channel, third channel, and fourth channel to the plurality of fibers;
• pre-curing the resin to form a pre-preg rib structure within the channels;
• and
• removing the pre-preg rib structure from the pre-preg mold;
• inserting the pre-preg rib structure into a part mold;
• overlaying the pre-preg rib structure with a composite pre-preg panel;
• and
• curing the pre-preg rib structure and the composite pre-preg panel within the part mold to fuse the pre-preg rib structure with the composite pre-preg panel.