| US 7,575,650 B1 | ||
| End gaps of filled honeycomb | ||
| Chandrakant Himatlal Shah, Burbank, Calif. (US); Tod Palm, Manhattan Beach, Calif. (US); Timothy Alan Dyer, Garden Grove, Calif. (US); and Carl A. Reis, Torrance, Calif. (US) | ||
| Assigned to Northrop Grumman Corporation, Los Angeles, Calif. (US) | ||
| Filed on Jun. 24, 2005, as Appl. No. 11/166,323. | ||
| Application 11/166323 is a division of application No. 10/461178, filed on Jun. 12, 2003, granted, now 7,048,986. | ||
| Int. Cl. B32B 37/00 (2006.01) | ||
| U.S. Cl. 156—78 [156/79; 156/290; 156/292] | 9 Claims |
| 1. A method for forming a sandwich panel comprising:
disposing a foam fill within a plurality of cells of a honeycomb core until said foam fill is of a predetermined height, the
foam fill and the honeycomb core defining a first gap region and a second gap region within each cell, the first gap region
proximate to a first surface of the honeycomb core, the second gap region proximate to a second surface of the honeycomb core;
adhering a first skin to the first surface of the honeycomb core with an adhesive; and
adhering a second skin to the second surface of the honeycomb core with the adhesive to form a panel, the panel having a surface
area of at least 2.25 square feet;
wherein disposing the foam fill within the cells of the honeycomb core comprises:
placing the honeycomb core on a form so as to fill a first end portion of each of the plurality of cells;
disposing the foam fill within the cells of the honeycomb core, the foam fill supported by the form such that the first end
portion remains free of the foam fill; ceasing to dispose the foam fill before the cells are completely full such that a second
end portion is free of foam fill; and
removing the honeycomb core from the form, the first end portion forming the first gap region, the second end portion forming
the second gap region.
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