Abstract: A formed core comprising a first and second plurality of pyramidal frustum bases, the first plurality of pyramidal frustum bases extending in a first direction and the second plurality of pyramidal frustum bases extending in a second direction, and wherein each pyramidal frustum base comprises: a node comprising a convex regular polygon, the convex regular polygon comprising a plurality of sides oriented in a first plane and wherein each side of the polygon of the node of each of the first plurality of pyramidal frustum bases is parallel to a side of the polygon of the node of at least one of the second plurality of pyramidal frustum bases; a plurality of faces extending from each of the sides of the polygon of each node of the first plurality of frustum bases to a side of the polygon of each of the second plurality of frustum bases.

Abstract: A multi-layered honeycomb structure adapted to reduce and/or eliminate thermal deformation is disclosed herein. In some embodiments, walls of the honeycomb structure comprise a first layer, optionally, a second layer, and a core layer adjacent to the first layer or between the first and second layers. The first and second layers may be compositions of Inconel or other high strength materials. The core layer may be copper or another thermally conductive material. The core layer is adapted to transmit heat between a first region of a structure and a second region. In this manner, heat can be transferred from the heated region to an unheated region, thereby reducing the temperature difference between the regions and thus the amount of thermal deformation.

Abstract: A formed core comprising a first and second plurality of pyramidal frustum bases, the first plurality of pyramidal frustum bases extending in a first direction and the second plurality of pyramidal frustum bases extending in a second direction, and wherein each pyramidal frustum base comprises: a node comprising a convex regular polygon, the convex regular polygon comprising a plurality of sides oriented in a first plane and wherein each side of the polygon of the node of each of the first plurality of pyramidal frustum bases is parallel to a side of the polygon of the node of at least one of the second plurality of pyramidal frustum bases; a plurality of faces extending from each of the sides of the polygon of each node of the first plurality of frustum bases to a side of the polygon of each of the second plurality of frustum bases.

Abstract: Methods and apparatus for transmitting a fluid through the core of a metal sandwich structure. Improved metal sandwich sheet structures include a formed metal core that is brazed, welded, or bonded to two outer flat metal sheets at a series of interleaving surface regions. The inventor has recognized that fluids (e.g., liquid and/or gaseous substances) can be transmitted through the cavities of these structures in order to accomplish thermal conduction or as a means of servicing particular regions of a building, vehicle, device, or other work of construction.

Abstract: A method and apparatus for producing a metal core sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed metal core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be brazed or bonded with corresponding external metal sheets on both sides of the formed metal core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger brazing or bonding joints to be formed between the metal core and the external metal sheets by facilitating improved capillary action by the metal core during the brazing or bonding process.

Abstract: A method and apparatus for producing a sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be bonded with corresponding external sheets on both sides of the formed core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger bonding joints to be formed between the core and the external sheets by facilitating improved capillary action by the core during the bonding process.

Abstract: A method and apparatus for producing a metal core sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed metal core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be bonded with corresponding external metal sheets on both sides of the formed metal core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger bonding joints to be formed between the metal core and the external metal sheets by facilitating improved capillary action by the metal core during the bonding process.

Abstract: A multi-layered honeycomb structure adapted to reduce and/or eliminate thermal deformation is disclosed herein. In some embodiments, walls of the honeycomb structure comprise a first layer, optionally, a second layer, and a core layer adjacent to the first layer or between the first and second layers. The first and second layers may be compositions of Inconel or other high strength materials. The core layer may be copper or another thermally conductive material. The core layer is adapted to transmit heat between a first region of a structure and a second region. In this manner, heat can be transferred from the heated region to an unheated region, thereby reducing the temperature difference between the regions and thus the amount of thermal deformation.

Abstract: A method and apparatus for producing a metal core sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed metal core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be brazed or bonded with corresponding external metal sheets on both sides of the formed metal core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger brazing or bonding joints to be formed between the metal core and the external metal sheets by facilitating improved capillary action by the metal core during the brazing or bonding process.

Abstract: A method and apparatus for producing a metal core sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed metal core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be brazed or bonded with corresponding external metal sheets on both sides of the formed metal core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger brazing or bonding joints to be formed between the metal core and the external metal sheets by facilitating improved capillary action by the metal core during the brazing or bonding process.

Abstract: A method and apparatus for producing a metal core sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed metal core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be bonded with corresponding external metal sheets on both sides of the formed metal core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger bonding joints to be formed between the metal core and the external metal sheets by facilitating improved capillary action by the metal core during the bonding process.

Abstract: Methods and apparatus for transmitting a fluid through the core of a metal sandwich structure. Improved metal sandwich sheet structures include a formed metal core that is brazed, welded, or bonded to two outer flat metal sheets at a series of interleaving surface regions. The inventor has recognized that fluids (e.g., liquid and/or gaseous substances) can be transmitted through the cavities of these structures in order to accomplish thermal conduction or as a means of servicing particular regions of a building, vehicle, device, or other work of construction.

Abstract: A method and apparatus for producing a sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be bonded with corresponding external sheets on both sides of the formed core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger bonding joints to be formed between the core and the external sheets by facilitating improved capillary action by the core during the bonding process.

Abstract: A honeycomb cell structure has a plurality of first strips each formed into a generally zig-zag configuration and placed side by side to form a plurality of rows of cells in a generally honeycomb configuration with nodes between adjacent cells in each row, and a plurality of second strips of brazing foil. Each second strip is positioned between a respective pair of adjacent first strips and the first and second strips are secured together at each node such that a brazing foil strip extends across each cell in each row of the honeycomb. The second strips have a series of spaced slits extending transversely from at least one side edge across at least a distance equal to greater than half of the width of the second strip, with at least some of the slits being located within the cells.

Abstract: A golf club head for impacting a golf ball is disclosed. A wooden club body has a phenolic insert embedded in the center of the body ball striking face. The insert is secured in place in a vertical channel in the body striking face by solidified epoxy which interlocks communicating passages formed in the sides of the body channel and cavities in the insert. A metal honeycomb structure is supported in a central slot in the insert. A resin compound fills and covers the honeycomb structure. The exterior surface of the resin covering the honeycomb structure provides the intended golf ball impact surface of the golf club head.

Abstract: A golf putter head has a body with a cavity in its front face containing an insert member having a front, ball striking face co-planar with the front face of the body. The insert member comprises a honeycomb cellular structure with the cells of the structure filled with a resilient, epoxy material. The walls of the cellular structure are mounted in the cavity perpendicular to the inclined club striking face surface and have exposed cell edges co-planar with the surface of the resilient material and the club striking face surface for simultaneously impacting a golf ball. The putter head is further formed to have an upwardly curving sole. A curved neck attaches the head to the club shaft to position the striking face in line with the axis of the club shaft.