Abstract: A method for producing porous graphite for use as bone replacement with a structure for osteon penetration. Graphite is produced with ordered circular pores of 100 to 1000 microns in diameter covering at least 25% of the exposed surfaces. A cylindrical fiber is coated with a carbon flour-pitch mix and is then wound on a bobbin in a predetermined manner. The product of winding is dried, pressed, carbonized, and then graphitized. The fibers are removed either chemically or by volatilization during carbonization or graphitization.

Abstract: A lightweight metallic honeycomb core panel structure having a high strength, a highly contoured surface and possessing relatively low thermal conductivity through the panel is prepared by bonding a first adhesive sheet and a peel-ply cloth to one edge surface of a honeycomb core prior to contouring the core into the desired shape with the first sheet applied to the surface which becomes the convex side of the panel. Sufficient force is applied to the sheet in order to force the edge of the honeycomb core through the uncured adhesive and the sheet is bonded to the core forming a structural fillet. The core is then contoured to the desired shape with the peel-ply acting to prevent spreading of node bonds at the convex surface. A second sheet also comprising an uncured adhesive material and a peel ply cloth is bonded onto the second side of the core so that a fillet is formed on the core cell walls. The peel-ply cloths are then removed to expose a bondable surface.

Abstract: A method of tacking a honeycomb core to a base sheet, the core member having coatings of adhesive, one provided on the ends of the cells of each face of the core. The core is engaged with the base sheet so that one coating of adhesive contacts the base sheet while moving the core and the base sheet as a unit along a rectilinear path of travel. While engaging the core with the base sheet, the base sheet is (a) heated to temperatures within a wetting temperature of the adhesive but below the curing temperature of the adhesive, (b) maintained at temperatures within said wetting temperature range for a time sufficient to allow the one coating of adhesive to be heated, to flow and to form a fillet between the base sheet and the core but insufficient to allow undue heating of the other coating of adhesive, and (c) the base sheet, the adhesive, and the core are rapidly cooled to a discharge temperature which is below the wetting temperature range of the adhesive, thereby to tack the core to the base sheet.

Abstract: A mastic composition formed of a substantially homogeneous imporous mixture of a predetermined volume of low-density expanded closed-cell synthetic resin beads and a slurry prepared from calcined gypsum and water wherein the interstitial volume of the expanded beads is not substantially less than the volume of slurry. The substantially homogeneous mixture is self-adhering as a thick layer on an inverted smooth surface and yet separable therefrom as an integral layer, the mastic composition setting to a hard, strong, dimensionally stable, heat- and sound-retardant material. Method of mixing mastic compositions, and composite structural panels utilizing mastic compositions as well as the methods and apparatus for forming such panels are also disclosed.

Abstract: An environmentally durable, aluminum honeycomb structure is obtained by surface treatment and application of a polymeric film forming substance to the aluminum foil used in manufacture of honeycomb core prior to application of the adhesive and expanding the stacked and bonded core whereby the cells of the honeycomb core structure are formed. By application of a polymeric film forming substance before bonding, all surfaces of the honeycomb core are protected from corrosion and other environmental degradations. The presence of a polymeric film forming substance on honeycomb core surfaces aids in the formation of strong core-to-face sheet bonds by improving the fillet configuration and thereby the strength obtained in face sheet-to-core bonding.

Abstract: An expandable honeycomb structure adapted to be suspended between stacks of articles of freight or between a stack of articles of freight and a wall and having spaced strips of relatively stiff material defining certain cell walls to resist sagging of the structure by its own weight and undue "hour glass" distortion due to vertical elongation of certain of the cells. In one embodiment readily foldable strips are interspersed with relatively stiff strips of corrugated paperboard having their corrugations running lengthwise.

Abstract: A lock core panel wherein a face sheet, base sheet and core are integrally joined at each web line by fiber material prior to curing. The upper face sheet comprises layers which may be angularly oriented and selected fibers or strands removed, if desired, to provide desired porosity for noise suppression purposes.

Abstract: Unexpanded structural honeycomb material formed of permanently creasable material is extended in its expansion direction and compressed perpendicular to the expansion direction, e.g. between pressure rollers, so that the cells adopt a configuration in which they have dimensions in the expansion direction which are large compared with their dimensions in the direction of compression and the creasable material is creased. On subsequently being allowed to expand, the material adopts a self-sustaining open cellular configuration.

Abstract: A mastic composition formed of a substantially homogeneous imporous mixture of a predetermined volume of low-density expanded closed-cell synthetic resin beads and a slurry prepared from calcined gypsum and water wherein the interstitial volume of the expanded beads is not substantially less than the volume of slurry. The substantially homogeneous mixture is self-adhering as a thick layer on an inverted smooth surface and yet separable therefrom as an integral layer, the mastic composition setting to a hard, strong, dimensionally stable, heat- and sound-retardant material. Methods of mixing mastic compositions, and composite structural panels utilizing mastic compositions as well as the methods and apparatus for forming such panels are also disclosed.

Abstract: A method and apparatus of continuously producing a cellular structure wherein plies of flexible sheets are fed under tension, one through a glue station wherein precisely aligned longitudinal lines of adhesive are applied to a first face of one of the plies which are then adhered along said lines, followed by passing the resultant adhered plies as a web through a second station under tension where precisely aligned longitudinal lines of adhesive are applied to an exterior web face, and such web then fed as a continuous loop to intermittent web drive means. The web is intermittently fed into a cutting zone in precise increments and sheared to form successive strips that are forced into an assembly zone where the strips are adhered together to form an expandable cellular structure suitable for direct expansion and use as a honeycomb core. The loop provides a preformed unrestrained surge section ahead of the intermittent feed to accommodate in such section.

Abstract: A structural product useful in making skis and other articles of manufacture includes a core comprising a multiplicity of cells of structural material arranged side by side with their axes substantially parallel to each other and their ends open. A quantity of foamed plastic fills the cells and is bonded to the walls thereof. A structural skin lies across at least one face of the core and is bonded to the open ends of the component cells, thereby rigidifying the product.

Abstract: A method of manufacturing a body or frame for a valise, suitcase, attache case, or other similar article made of shaped plastic material, which is adapted for travel and personal use. A base or body frame is manufactured from a preferably profiled plastic member having the shape of a strip or band which is cut to a length corresponding to the periphery of the article, and which is then shaped and assembled; or by providing a profiled member whose cross-section corresponds to the shape of the valise, suitcase, attache case or similar article, which is cut to a predetermined size; and a lid or valise cover frame which cooperates with the body in a novel shaping arrangement of the lid and the body, or through the intermediary of an appropriate recessed portion proximate their adjoining regions; and with a suitable bottom and sheathing adapted to be optionally attached in a known manner in order to form a finished valise structure.

Abstract: An inexpensive, lightweight reflective panel for solar-thermal collector modules of the type including a parabolic reflector for reflecting incident solar radiation onto a fluid carrying conduit positioned along the focal axis of the reflector. A rigid, waterproof, honeycomb panel formed from paper and having a uniform thickness of parabolic shape supports a reflective material. Glass fiber cloth adhered to the outer panel surfaces adds to the panel's strength and rigidity. An adjustable support system suspends the reflective panel from the fluid carrying conduit and provides a means of adjusting panel curvature to precisely obtain the required parabolic shape.Methods of forming the panels are described which permit the panels to be formed at or near the site of their installation to obviate shipping problems and expense.

Abstract: A method of manufacturing a filter media having plyed sections of obliquely oriented honeycomb cells is disclosed as well as a novel filter media of stacked sections of obliquely oriented honeycomb cells.