The Boeing Company

Richard Q Taylor

Yukimori Moji

A method of fabricating a honeycomb core sandwich structure with an embedded fastener and the resulting structure are disclosed. The method comprises laying down a first nonmetallic synthetic layer (11), preferably a graphite epoxy layer, which may be cured or uncured. Bonded to the first nonmetallic synthetic layer is a honeycomb core layer (15) into which one or more flush head fasteners (25) have been inserted. The flush head fasteners are inserted into holes (13) in the honeycomb core that have an indentation (19) at one end that is configured to mate with the underside (21) of the head (23) of a flush head fastener (25). Bonding is accomplished by priming the walls of the honeycomb core layer adjacent the surfaces of the layer, and the fastener, with a suitable primer, preferably before the fastener is installed, and, coating one of the surfaces of the first nonmetallic synthetic layer (11) with a suitable adhesive before joining the first nonmetallic synthetic layer (11) to the surface of the honeycomb core layer (15) containing the head (23) of the flush head fastener (25). Thereafter, the cells of the honeycomb core that surround the fastener are filled with a potting material (35). Then, a second nonmetallic synthetic layer (37) is bonded to the surface of the honeycomb core remote from the surface to which the first nonmetallic synthetic layer (11) is bonded.

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Tukwila, WA, United States of America

Richard Q Taylor