Method for manufacturing a core composite provided with cover layers on both sides

Abstract

The invention relates to a method for manufacturing flat, single or double curved core composites 1, 23 with at least one folded honeycomb core 4, 19. Prior to applying the initially not yet hardened cover layers 2, 3, 13, 22 a curable and later removable core filler material 15, 16 is introduced into full-length drainage-enabling channels 5, 6 of the folded honeycomb core 4, 19 in order to prevent telegraphing of the cover layers 2, 3, 13, 22 into the channels 5, 6 of the folded honeycomb core when arranging and/or hardening the cover layers 2, 3, 13, 22 and to produce edge-free and polygon-free surfaces of the core composite 1, 23. The core composites 1, 23 made according to the method have optimum structural mechanical properties, an ideal surface quality from the aerodynamic and aesthetic point of view, whereby a direct reprocessing of the core composites 1, 23 is possible without the need for further time and cost-intensive as well as in some circumstances weight-increasing finishing steps. With the method it is possible to manufacture in particular one-piece fuselage sections with wound core composites 1, 23 with a folded honeycomb 4, 19 as well as shell segments with laid cover layers 2, 3, 13, 22 for longitudinally divided (segmented) fuselage sections for large aircraft.

Dependencies are inferred from the claim text.