Single stage hot bonding method for producing composite honeycomb core structures

A single stage hot bonding process for forming composite honeycomb core structures comprising the steps of:

• bonding a primary load carrying honeycomb core to an edge of a shape defining honeycomb core to form a combined honeycomb core;
• forming opposed undercut regions in said combined honeycomb core in the region of said primary load carrying honeycomb core by reducing the thickness of said primary load carrying honeycomb core to less than the thickness of said shape defining honeycomb core;
• placing a first skin on a working surface;
• applying adhesive to the exposed side of said first skin;
• attaching a first spar cap to said first skin;
• applying adhesive to the exposed side of said first spar cap;
• attaching said combined honeycomb core to said first spar cap and said first skin such that one of said opposed undercut regions of said combined honeycomb core overlies and is attached to said first spar cap and the surface of said shape defining honeycomb core portion of said combined honeycomb core adjacent to said undercut region overlies and is attached to said first skin;
• applying adhesive to the exposed side of said combined honeycomb core;
• attaching a second spar cap to the other one of said opposed undercut regions of said combined honeycomb core;
• applying adhesive to the exposed side of said second spar cap;
• attaching a second skin to said second spar cap and said exposed side of said combined honeycomb core;
• and,
• simultaneously heating said attached combined honeycomb core, said first and second spar caps and said first and second skins to cure said adhesives and simultaneously form bonds between said combined honeycomb core, said first and second spar caps and said first and second skins where they join.