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 compositeswith at least one folded honeycomb core. Prior to applying the initially not yet hardened cover layersa curable and later removable core filler materialis introduced into full-length drainage-enabling channelsof the folded honeycomb corein order to prevent telegraphing of the cover layersinto the channelsof the folded honeycomb core when arranging and/or hardening the cover layersand to produce edge-free and polygon-free surfaces of the core composite. The core compositesmade 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 compositesis 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 compositeswith a folded honeycombas well as shell segments with laid cover layersfor longitudinally divided (segmented) fuselage sections for large aircraft.