Abstract: A method of producing a unitary curved structure having a honeycomb core by coating a mold with gel, applying a layer of reinforced fiberglass plastic to the gel to receive, after partial curing, a light layer of chopped glass fibers (about 3/4 ounces/sq. ft.) and a mixture of catalyzed resin and chopped fiber strand. The resulting surface may be rolled to remove bubbles and oversprayed with catalyzed resin. A Raw Kraft paper honeycomb is placed into the wet laminate and completely covered with wax paper weighted with sand bags to approximately 10 pounds per square foot to press the honeycomb into place and seal same. The resin is absorbed in and climbs the honeycomb walls, and heat and styrene gas are liberated into the cells. The bags and wax paper are removed after partial cure, excess styrene fumes are blown away, and the honeycomb is lightly oversprayed with a catalyzed resin.

Abstract: A solar collector panel and a method of making the collector panel. The solar collector panel has four layers of fiberglass mat which are each saturated with a catalyzed liquiform resin. Between the first two layers, unimpregnated Kraft honeycomb paper having an open cellular structure is placed so as to form a resinated honeycomb core between these first two layers. A plurality of fluid channels are then bonded to the second layer of resin saturated fiberglass mat. The fluid channels are made of a material having a coefficient of thermal expansion essentially equal to that of the fiberglass mat. The third layer of resin-saturated fiberglass mat is placed over the fluid channels. A second layer of Kraft honeycomb paper is then placed between the third and fourth layers of resin-saturated fiberglass mat, and a clear gel coat mixed with an ultraviolet inhibitor solution is rolled out over the top of the solar collector panel to partially screen out ultraviolet rays.

Abstract: A solar collector panel and method of making same are disclosed. The solar collector panel has four layers of fiberglass mat which are each saturated with a catalyzed liquiform resin. Between the first two layers, unimpregnated Kraft honeycomb paper having an open cellular structure is placed so as to form a resinated honeycomb core between these first two layers. A black gel coat is sprayed onto the second layer of resin-saturated fiberglass mat and a plurality of copper tubes are then placed onto the black gel coat so as to be bonded in heat-transfer relation thereto. The third layer of resin-saturated fiberglass mat is draped over the copper tubes so as to insulate them. A second layer of Kraft honeycomb paper is then placed between the third and forth layers of resin-saturated fiberglass mat, and a clear gel coat mixed with an ultraviolet inhibitor solution is rolled out over the top of the solar collector panel to partially screen out ultraviolet rays.