FIELD OF EMBODIMENTS OF THE DISCLOSURE

Embodiments of the present disclosure generally relate to composite panels, and, more particularly, to methods of forming composite panel systems.

BACKGROUND OF THE DISCLOSURE

Various structures are formed from composite materials. For example, portions of aircraft, such as wings, may be formed from composite materials. The composite material may be or include a polymer matrix reinforced with fibers. The fibers may be bound together with polymers, such as epoxy. Known fibers include glass, carbon, basalt, aramid, or the like.

Internal cabins of aircraft may include numerous composite panels. Composite panels such as sidewall and doorway liners within an internal cabin typically do not include exposed core along edges. The core is covered due to aesthetics, acoustics, and to prevent, minimize, or otherwise reduce potential moisture infiltration.

In order to cover edges of a composite panel, an edge wrapping process is used. Typically, a decorative laminate is wrapped around an edge and glued to a back side of the panel.

For at least certain composite panels, an edge wrapping process is not amenable to automation. Instead, the edge wrapping process is typically performed manually. The process of manually edge wrapping a laminate around an edge of a composite panel is time and labor intensive. Moreover, such a manual edge wrapping process may be ergonomically awkward.

SUMMARY OF THE DISCLOSURE

A need exists for a system and method for efficiently covering a peripheral edge of a composite panel. Further, a need exists for a system of method for automatically covering a peripheral edge of a composite panel.

With those needs in mind, certain embodiments of the present disclosure provide a composite panel assembly including a core, an inner skin coupled to a first side of the core, and an outer skin coupled to a second side of the core. A peripheral edge including portions of the core, the inner skin, and the outer skin, is compressed to close a path into the core.

In at least one embodiment, a decorative laminate is coupled to the inner skin. The peripheral edge also includes a portion of the decorative laminate.

In at least one embodiment, the core is a honeycomb core including a plurality of interconnected honeycomb cells. The inner skin and the outer skin include one or more pre-impregnated epoxy layers.

In at least one embodiment, the peripheral edge is rounded. In at least one embodiment, the peripheral edge includes a bend.

The peripheral edge is thinner than a main portion of the composite panel assembly.

In at least one embodiment, a closeout spline couples the composite panel assembly to another composite panel assembly. In at least one embodiment, the closeout spline includes an upstanding wall, and covering ribs coupled to the wall. A distal end of the peripheral edge may be wedged between an interior surface of the upstanding wall and an exterior surface of one of the covering ribs.

Certain embodiments of the present disclosure provide a method of forming a composite panel assembly that includes providing a core, coupling an inner skin to a first side of the core, coupling an outer skin to a second side of the core, compressing a peripheral edge including portions of the core, the inner skin, and the outer skin, and closing a path into the core by the compressing.

In at least one embodiment, the method also includes coupling a decorative laminate to the inner skin. The compressing also includes compressing a portion of the decorative laminate.

In at least one embodiment, the compressing includes rounding the peripheral edge. In at least one embodiment, the compressing includes bending the peripheral edge.

The method may also include coupling the composite assembly to another composite assembly with a closeout spline. In at least one embodiment, the method also includes wedging a distal end of the peripheral edge between an interior surface of an upstanding wall of the closeout spline and an exterior surface of a covering rib of the closeout spline.

Certain embodiments of the present disclosure provide a composite panel system that includes a first composite panel assembly, and a second composite panel assembly. Each of the first composite panel assembly and the second composite panel assembly includes a core, an inner skin coupled to a first side of the core, and an outer skin coupled to a second side of the core. A peripheral edge including portions of the core, the inner skin, and the outer skin, is compressed to close a path into the core.

In at least one embodiment, the first composite panel assembly is separated from the second composite panel assembly by a gap. A closeout spline couples the first composite panel assembly to the second composite panel assembly. The closeout spline includes an upstanding wall, and covering ribs coupled to the wall. A distal end of each of the peripheral edges is wedged between an interior surface of the upstanding wall and an exterior surface of one of the covering ribs.

