Abstract: A composite structure and method for constructing same for use in fabricating the framework of a spacecraft is disclosed. The structure is cut from flat sheets of composite laminate materials, and then assembled. The use of tenons and mortises provides for self-fixturing and adhesive bonding of the structural components.

Abstract: A guide rail assembly for clamping circuit boards in place comprising a guide rail directly attached to a heat radiating fin formed from a graphite fiber reinforced plastic. The fins have tenons that fit within the guide rail to provide additional resistance to clamping forces. The guide rail assembly can be assembled using a variety of bonding methods, including adhesives.

Abstract: A method for forming a layer of very uniform low density foam of uniform thickness on a surface is disclosed. A screen is positioned at a selected distance above a structure surface. The screen is positioned by lowering a tautly stretched screen over a plurality of studs upstanding from the structure surface to a selected height above said surface. A liquid, self-rising foam material is sprayed through the screen onto the structure surface. As the foam rises, it penetrates through the screen, leaving irregular projections above the screen. After the foam cures to at least a self-sustaining state, the screen is stripped away, leaving a uniform foam layer. The foam layer is bonded to the surface as it cures. Since the screen offers very little resistance to the rising foam, the resulting foam layer has a very uniform low density, highly desirable for thermal insulation application.

Abstract: An apparatus for forming a layer of low density foam of uniform thickness on a surface is disclosed. A plurality of upstanding studs spaced across the surface to be coated support a taut screen at a selected height above the surface. An applicator applies liquid, self-rising foam material in a uniform manner to said surface through said screen. As the foam rises, it penetrates through the screen, leaving irregular projections above the screen. After the foam cures to at least a self-sustaining state, the screen is stripped away, leaving a uniform foam layer. Since the screen offers very little resistance to the rising foam, the resulting foam layer has a very uniform low density, highly desirable for thermal insulation application.

Abstract: An apparatus for continuously coating a large surface with a foam layer having uniform low density and uniform thickness. The coating apparatus is positioned adjacent to the surface to be coated, with the surface movable past the apparatus in a direction substantially in the plane of the surface. The coating apparatus includes a plurality of self-rising foamable liquid application means for continuously applying the liquid to the surface. Immediately downstream, a screen positioning means moves a screen substantially parallel to the surface without relative motion therebetween. As the foam rises, it penetrates slightly through the screen and cures to a self-sustaining state. A rotatable brush then engages the upper surface of the screen to abrade and comminute the excess foam extending through the screen. Further means are provided to remove the comminuted excess foam and to lift the screen and any remaining excess foam away from the surface of the resulting uniform foam layer.