IP Library › Granted Patent US 9,987,832
Granted Patent B2
US 9,987,832 · App. 14/631,790 · Granted Jun 5, 2018

Honeycomb sandwich panel paint ready surface

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Quick Facts
Patent No.
US 9,987,832
App. No.
14/631,790
Granted
Jun 5, 2018
Kind
B2
Abstract

A method for curing a composite panel, including the steps of inserting a Biaxially Oriented Polypropylene release film into a mold, and curing the panel using a cold-in/cold-out process at a lowermost temperature within the panel's temperature curing range. The process further includes the use of a twice smoothed caul sheet, where the smoothing includes a coarse sanding and a fine sanding.

Claims (28)

1. A method for curing a composite panel, comprising:

placing a release film onto a mold;

laying up the composite panel on the release film on the mold;

initiating curing of the composite panel within the mold at a first curing temperature within a lowermost ten percent of a cure temperature range of a material of the composite panel;

maintaining, as a first curing stage, curing of the composite panel within the mold at the first curing temperature;

continuing curing of the composite panel within the mold at a second curing temperature above the lowermost ten percent of the cure temperature range;

maintaining, as a second curing stage, curing of the composite panel within the mold at the second curing temperature;

completing curing of the composite panel within the mold at a third curing temperature within the lowermost ten percent of the cure temperature range; and

maintaining, as a third curing stage, curing of the composite panel within the mold at the third curing temperature.

2. The method of claim 1 , wherein the composite panel includes a thermosetting polymer matrix.

3. The method of claim 1 , wherein the composite panel includes an epoxy matrix.

4. The method of claim 1 , wherein the composite panel includes a phenolic matrix.

5. The method of claim 1 , wherein the composite panel includes a bismaleimide matrix.

6. The method of claim 1 , wherein the composite panel includes a cyanate ester matrix.

7. The method of claim 1 , wherein the composite panel includes a polyester matrix.

8. The method of claim 1 , wherein the composite panel includes a vinyl ester matrix.

9. The method of claim 1 , wherein the composite panel includes a glass fiber.

10. The method of claim 1 , wherein the composite panel includes a carbon fiber prepeg.

11. The method of claim 1 , wherein the composite panel includes an aramid fiber core.

12. The method of claim 1 , wherein the release film is a biaxially oriented polypropylene release film.

13. The method of claim 1 , wherein the resultant composite panel is paint ready without need for fill and fare.

14. The method of claim 1 , wherein the release film exhibits reduced compression in view of conventional release films, thereby minimizing core telegraphing in the composite panel upon curing.

15. The method of claim 1 , wherein the composite panel is configured for use as an aircraft interior panel.

16. The method of claim 1 , wherein the composite panel is configured for use as an aircraft structural panel.

17. The method of claim 1 , wherein laying up the composite panel comprises placing a prepeg and a core onto the mold.

18. The method of claim 17 , wherein the core is a honeycomb core.

19. The method of claim 17 , wherein the prepeg is an epoxy resin prepeg.

20. The method of claim 1 , wherein the resultant composite panel is paint ready without need for a surfacing film.