Composite panel with fixed void content and methods of making same

A method for manufacturing a composite panel having a desired void content comprising:

• laying on a surface a first ply of resin, the first ply having a predetermined length and height;
• provisionally dividing the first ply along its length into a first section and a second section;
• placing on the first section a first filament and a second filament, a length of the first filament and a length of the second filament being at least equal to the height of the first ply;
• placing on the second section a third filament and a fourth filament, a length of the third filament and a length of the fourth filament being at least equal to the height of the first ply, and a distance between the third filament and the fourth filament being greater than a distance between the first filament and the second filament;
• laying a second ply of resin atop the first ply and the first, second, third, and fourth filaments to form a first intermediate composite panel;
• curing the first intermediate composite panel in an autoclave to form a second intermediate composite panel;
• and
• submerging the second intermediate composite panel in a solution that dissolves the first, second, third, and fourth filaments, leaving void space in their place;
• wherein:
• the first, second, third and fourth filaments are chromic gut sutures;
• a diameter of the first and second filaments is generally equal;
• a diameter of the third and fourth filaments is generally equal and different from the diameter of the first and second filaments.

A method for making a multi-ply composite panel having a desired void volume comprising:

• laying on a surface a first ply of resin, the first ply having a predetermined length and height;
• provisionally dividing the first ply along its length into a first section, a second section, and a third section;
• placing on the first section a first filament and a second filament, a length of the first filament and a length of the second filament being at least equal to the height of the first ply;
• placing on the second section a third filament and a fourth filament, a length of the third filament and a length of the fourth filament being at least equal to the height of the first ply, and a distance between the third filament and the fourth filament being greater than a distance between the first filament and the second filament;
• placing on the third section a fifth filament and a sixth filament, a length of the fifth filament and a length of the sixth filament being at least equal to the height of the first ply, and a distance between the fifth filament and the sixth filament being greater than a distance between the third filament and the fourth filament;
• laying a second ply of resin atop the first ply and the first, second, third, fourth, fifth and sixth filaments;
• provisionally dividing the second ply along its length into a fourth section, a fifth section, and a sixth section, the fourth section being upwardly adjacent the first section, the fifth section being upwardly adjacent the second section, and the sixth section being upwardly adjacent the third section;
• placing on the fourth section a seventh filament and an eighth filament, a length of the seventh filament and a length of the eighth filament being at least equal to the height of the second ply;
• placing on the fifth section a ninth filament and a tenth filament, a length of the ninth filament and a length of the tenth filament being at least equal to the height of the second ply, and a distance between the ninth filament and the tenth filament being greater than a distance between the seventh filament and the eighth filament;
• placing on the sixth section an eleventh filament and a twelfth filament, a length of the eleventh filament and a length of the twelfth filament being at least equal to the height of the second ply, and a distance between the eleventh filament and the twelfth filament being greater than a distance between the ninth filament and the tenth filament;
• laying a third ply of resin atop the second ply and the seventh, eighth, ninth, tenth, eleventh, and twelfth filaments to form to form a first intermediate composite panel;
• curing the first intermediate composite panel in an autoclave to form a second intermediate composite panel;
• and
• submerging the second intermediate composite panel in a solution that dissolves each of the filaments.

A method for making a porous composite panel having a desired void content comprising:

• forming a laminate;
• the laminate comprising a first ply of resin and a second ply of resin with an individual first suture and an individual second suture placed therebetween;
• curing the laminate in an autoclave to form an intermediate composite panel;
• and submerging the intermediate composite panel in a proteases enzyme solution that dissolves the first suture and the second suture;
• wherein the first suture and the second suture comprise chromic gut;
• and
• wherein a diameter of the first suture is different from a diameter of the second suture.