Method of laminating structural members

Abstract

A laminate is obtained by providing a lightweight core material, such as a honeycombed plastic or metal, within the cavity defined by an annular mold cavity frame. Face sheets, which are to be bonded to the core material, are provided on opposite sides of the frame and extend over the frame, thus sealing the core material in the cavity. An adhesive is provided between the core material and the face sheets and the combined thickness of the core material and adhesive is a close fit within the opposed face sheets. A gas tight seal, such as an O-ring gasket, is provided between the frame and the face sheet members to form a gas tight cavity between the face sheet members and the frame. External heat and pressure are used to bond the face sheets to the core material. Gas pressure is introduced into the sealed cavity to minimize out-gasing of the adhesive.