METHOD OF INTEGRALLY FORMING RIBS IN A COMPOSITE PANEL

1 . A method of integrally forming 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.

2 . The method of claim 1 , further comprising:

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 the second fiber sheet such that a subset of the second plurality of fibers are displaced about the protrusion and into each of the respective third channel and fourth channel; and

applying a resin within each of respective third channel and fourth channel to the plurality of fibers.

3 . The method of claim 2 , wherein the wedge-shaped protrusion includes at least one of a conical portion and a pyramidal portion, and wherein the at least one of a conical portion and a pyramidal portion is configured to pierce through the first fiber sheet and the second fiber sheet.

4 . The method of claim 1 , further comprising:

inserting the pre-preg rib structure into a part mold;

overlaying the pre-preg rib structure with a composite pre-preg panel;

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.

5 . The method of claim 3 , wherein curing the pre-preg part within the part mold includes heating and applying pressure to the pre-preg part.

6 . The method of claim 1 , wherein the step of extending the wedge-shaped protrusion through the first fiber sheet is characterized by not severing any of the plurality of fibers.

7 . The method of claim 1 , wherein the plurality of fibers of the first fiber sheet are carbon fibers.

8 . 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.

9 . The method of claim 8 , further comprising:

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 the second fiber sheet such that a subset of the second plurality of fibers are displaced about the protrusion and into each of the respective third channel and fourth channel; and

applying a resin within each of respective third channel and fourth channel to the plurality of fibers.

10 . The method of claim 9 , wherein the wedge-shaped protrusion includes at least one of a conical portion and a pyramidal portion, and wherein the at least one of a conical portion and a pyramidal portion is configured to pierce through the first fiber sheet and the second fiber sheet.

11 . The method of claim 8 , wherein curing the pre-preg part within the part mold includes heating and applying pressure to the pre-preg part.

12 . The method of claim 8 , wherein the step of extending the wedge-shaped protrusion through the first fiber sheet is characterized by not severing any of the plurality of fibers.

13 . The method of claim 8 , wherein the plurality of fibers of the first fiber sheet are carbon fibers.

14 . 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.

15 . The method of claim 14 , wherein the wedge-shaped protrusion includes at least one of a conical portion and a pyramidal portion, and wherein the at least one of a conical portion and a pyramidal portion is configured to pierce through the first fiber sheet and the second fiber sheet.

16 . The method of claim 14 , wherein curing the pre-preg part within the part mold includes heating and applying pressure to the pre-preg part.

17 . The method of claim 14 , wherein the step of extending the wedge-shaped protrusion through the first fiber sheet is characterized by not severing any of the plurality of fibers.

18 . The method of claim 14 , wherein the plurality of fibers of the first fiber sheet are carbon fibers.