Abstract: A tool for forming a panel including a core area, at which plies sandwich a core, and a trim area surrounding the core, at which the plies are bonded together, is provided and includes a body having a surface on which the panel is formable, an assembly to apply bonding pressure to the plies at least at the core and trim areas and a clamping device external to the assembly to apply a clamping force to the vacuum bag and the plies.

Abstract: A composite structure includes a first laminate, a second laminate, and at least one core component located between the first laminate and the second laminate. The at least one core component includes a honeycomb core and at least one locking ply extending from the honeycomb core between the first laminate and the second laminate. The at least one locking ply is configured such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.

Abstract: A composite panel includes a support layer including a first plurality of prepreg plies wrapped around at least one mandrel; a mid-plane impact layer including a second plurality of prepreg plies, the mid-plane impact layer adjacent to the support layer; a upper skin layer including a third plurality of prepreg plies, the upper skin layer adjacent to the mid-place impact layer; and a lower skin layer including a fourth plurality of prepreg plies, the lower skin layer adjacent to the support layer; whereby each of the first, second, third, and fourth plurality of prepreg plies are co-cured to form the composite panel.

Abstract: A composite structure includes a first laminate and a second laminate. At least one core assembly is located between the first laminate and the second laminate. The at least one core assembly includes a core component and a layer of filler material disposed at a first face of the core component. The layer of filler material at least partially fills selected cells of the core component to a fill depth such that the filler material rigidizes when cured to prevent movement and/or crushing of core component under a pressure applied during a cure cycle of the composite structure.

Abstract: A caul system for a composite structure having one or more core elements includes a lattice grid hard caul selectively locatable at a portion of the composite structure without core elements. The caul system further includes a soft caul selectively locatable at a portion of the composite structure having a core element. A method of forming a composite structure with one or more core elements includes locating a first laminate in a tool and locating one or more core elements over the first laminate. A second laminate is located over the one or more core elements. A lattice grid hard caul is placed over the second laminate, avoiding locations having core elements of the one or more core elements disposed thereat. A soft caul is located over the one or more core elements, thereby preventing deformation of the one or more core elements.

Abstract: A kit for repairing an opening formed in a composite panel having a laminate skin arranged on opposing sides of a first core material is provided including a plug and a patch. The plug is formed from a second core material and has a cured filler material arranged within at least a portion of the second core material. The patch is formed from a plurality of cured first plies arranged in a stacked orientation. The plug is configured to be received within the opening of the composite panel and the patch is configured to cover the opening of the composite panel.

Abstract: A composite panel includes a support layer including a first plurality of prepreg plies wrapped around at least one mandrel; a mid-plane impact layer including a second plurality of prepreg plies, the mid-plane impact layer adjacent to the support layer; a upper skin layer including a third plurality of prepreg plies, the upper skin layer adjacent to the mid-place impact layer; and a lower skin layer including a fourth plurality of prepreg plies, the lower skin layer adjacent to the support layer; whereby each of the first, second, third, and fourth plurality of prepreg plies are co-cured to form the composite panel.

Abstract: A composite structure includes a first laminate and a second laminate. At least one core assembly is located between the first laminate and the second laminate. The at least one core assembly includes a core component and a layer of filler material disposed at a first face of the core component. The layer of filler material at least partially fills selected cells of the core component to a fill depth such that the filler material rigidizes when cured to prevent movement and/or crushing of core component under a pressure applied during a cure cycle of the composite structure.

Abstract: A caul system for a composite structure having one or more core elements includes a lattice grid hard caul selectively locatable at a portion of the composite structure without core elements. The caul system further includes a soft caul selectively locatable at a portion of the composite structure having a core element. A method of forming a composite structure with one or more core elements includes locating a first laminate in a tool and locating one or more core elements over the first laminate. A second laminate is located over the one or more core elements. A lattice grid hard caul is placed over the second laminate, avoiding locations having core elements of the one or more core elements disposed thereat. A soft caul is located over the one or more core elements, thereby preventing deformation of the one or more core elements.

Abstract: A caul plate system for a laminate structure includes a plurality of layers of curable caul plies disposed over a laminate structure and substantially conforming to a surface of the laminate structure. A resin is applied to the plurality of layers of caul plies. Co-curing of the plurality of layers of caul plies with the laminate structure hardens the plurality of layers of caul plies such that a normal pressure is applied to the laminate structure during cure of the laminate structure.

Abstract: A composite structure includes a first laminate, a second laminate, and at least one core component located between the first laminate and the second laminate. The at least one core component includes a honeycomb core and at least one locking ply extending from the honeycomb core between the first laminate and the second laminate. The at least one locking ply is configured such that a pressure applied during a cure cycle of the composite structure retains the at least one locking ply between the first laminate and the second laminate thereby preventing movement of core component.

Abstract: A method of sealing between two components includes applying and curing a layer of fay surface sealant to a first component. A layer of liquid shim is applied to one or more of the first component and a second component. The first component is assembled to the second component with the layer of fay surface sealant and the layer of liquid shim therebetween. An assembly of two components includes a first component and a layer of fay surface sealant applied and cured to a first facing surface of the first component. A second component includes a second facing surface, such that the second facing surface and the layer of fay surface sealant define a gap therebetween. A layer of liquid shim is located between the second component and the layer of fay surface sealant thereby substantially filling the gap.

Abstract: A tool for forming a panel including a core area, at which plies sandwich a core, and a trim area surrounding the core, at which the plies are bonded together, is provided and includes a body having a surface on which the panel is formable, an assembly to apply bonding pressure to the plies at least at the core and trim areas and a clamping device external to the assembly to apply a clamping force to the vacuum bag and the plies.

Abstract: A caul plate system for a laminate structure includes a plurality of layers of curable caul plies disposed over a laminate structure and substantially conforming to a surface of the laminate structure. A resin is applied to the plurality of layers of caul plies. Co-curing of the plurality of layers of caul plies with the laminate structure hardens the plurality of layers of caul plies such that a normal pressure is applied to the laminate structure during cure of the laminate structure.

Abstract: A tool for forming a panel including a core area, at which plies sandwich a core, and a trim area surrounding the core, at which the plies are bonded together, is provided and includes a body having a surface on which the panel is formable, the surface including core and trim portions for respective correspondence with locations of the core and trim areas of the panel, a border between the core and trim portions defining a surface feature displaced from a plane of the core portion, a lock disposable proximate to the surface feature to increase a pre-bonding friction between the plies at the surface feature and an assembly to apply bonding pressure to the plies and the lock at least at the core and trim areas.