Abstract: A cross-corrugated support structure includes a sheet having a first and a second set of corrugations. The first set of corrugations is defined by a series of alternating ridges and grooves that extend the length of the sheet in a first direction. The second set of corrugations is also defined by a series of ridges and grooves that extend the length of the sheet in a second direction that intersects with the first direction. The intersection of the first and second set of corrugations creates cross-corrugations throughout the sheet. To provide compressive and tensile strengths suitable for large-scale construction applications, the sheet may be made of a carbonaceous material such as carbon fiber or graphite treated to rigidly retain a shape including the first and second set of corrugations within the sheet. The sheet may be reinforced by securing support members or additional corrugated sheets to the sheet.

Abstract: A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

Abstract: A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

Abstract: A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

Abstract: A cross-corrugated support structure includes a sheet having a first and a second set of corrugations. The first set of corrugations is defined by a series of alternating ridges and grooves that extend the length of the sheet in a first direction. The second set of corrugations is also defined by a series of ridges and grooves that extend the length of the sheet in a second direction that intersects with the first direction. The intersection of the first and second set of corrugations creates cross-corrugations throughout the sheet. To provide compressive and tensile strengths suitable for large-scale construction applications, the sheet may be made of a carbonaceous material such as carbon fiber or graphite treated to rigidly retain a shape including the first and second set of corrugations within the sheet. The sheet may be reinforced by securing support members or additional corrugated sheets to the sheet.

Abstract: A method of manufacturing cross-corrugated support structures is provided. A mold having a molding surface with a first plurality and a second plurality of corrugations therein is used to introduce corrugations into a flexible, carbonaceous sheet. Cross-corrugations are introduced into the sheet by placing the sheet onto the molding surface, encapsulating the sheet to form a vacuum chamber, and evacuating the vacuum chamber of air. As air is evacuated from the vacuum chamber, the sheet is drawn upon the molding surface causing the sheet to conform to the shape of the molding surface. Thermosetting resin is infused into the sheet and cured causing the sheet to rigidly retain the shape of the molding surface. The sheet is further reinforced by securing at least one support member to the sheet using thermosetting resin.

Abstract: A tool for use in forming moulded articles, the tool comprising a tool body formed of a foamed material, a resinous material on the tool body and elastomeric material between said tool body and resinous material to inhibit the movement of resin from the resinous material into the tool body. The invention also provides a method of manufacturing a tool, a method of moulding articles using such a tool, and elastomeric material for use in forming a tool. One particular application of the tools of the present invention is in the formation or manufacture of moulded articles using curable, resinous composite materials.

Abstract: A mould tool (10) for moulding mouldable material, the mould tool comprises a tool body (12) having a plurality of tool body sections (14), at least two of which comprise an inner polymer foam core (16) within an outer skin (18) of resinous material and are stacked one above the other, the tool (10) further comprises a mould skin (20) extending over the body (12) to provide a mould surface (22) on which mouldable material can be moulded. A method of manufacturing such a mould tool and a tool body are also provided.

Abstract: Mould tools (10) particularly for use in moulding curable resinous composite materials, such as fibre-reinforced resinous materials, having a body (14) comprising a foamed ferrous/nickel alloy such as FeNi36, FeNi42 and/or FE-330Ni-4.5Co. The body (14) can be made of a single unit or of a plurality of units that would typically be secured together. A tool surface (12) is declined on a tool surface layer (20) of the body (14). The tool surface layer (20) can comprise a cured resinous material.

Abstract: Fiber-reinforced thermoplastic honeycomb is prepared in a continuous manner one half cell at a time by laying down a corrugated web of thermoplastic, with and without fiber-reinforcement atop a honeycomb, selectively fusing the node-antinode demes and repeating the process until a honeycomb of the desired depth is prepared.

Abstract: A continuous, substantially uniform tow useful in forming composite molded articles is prepared by forming a continuous tow of continuous carbon fibers, forming a continuous tow of thermoplastic polymer fibers to a selected width, uniformly and continuously spreading the carbon fiber two to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow, intermixing the tows intimately, uniformly and continuously, in a relatively tension-free state, and continuosuly withdrawing the intermixed tow.

Abstract: A composite article is prepared by forming a continuous tow of continuous carbon fibers, forming a continuous tow of thermoplastic polymer fibers, uniformly and continuously spreading the thermoplastic polymer fibers to a selected width, uniformly and continuously spreading the carbon fiber tow to a width that is essentially the same as the selected width for the thermoplastic polymer fiber tow, intermixing the tows intimately, uniformly and continuously, in a relatively tension-free state, continuously withdrawing the intermixed tow and applying the tow to a mold and heating the tow.

Abstract: A process and apparatus for the incineration of organic material, and particularly agricultural waste products, to produce useable energy, consists of exposing the material to elevated temperature in an excess of air in a cylindrical furnace which terminates at the top in a frustum of a cone, the furnace having tangential inlet means at the bottom and discharge means comprising a concentric hollow cylinder projecting into the bottom portion of the furnace; the process and apparatus are particularly useful in the preparation of siliceous compositions from materials such as rice hulls and the process can be conducted under conditions whereby a highly reactive amorphous form of silica is produced, which silica is useful as a component of hydraulic cements.