Abstract: A structural element for use in aerospace applications such as a structural element suitable as an aircraft component is described. The composite structure comprises: (a) a rib having a first end and a second end; (b) at least one member such as a face sheet having an inner surface and an outer surface; and (c) a rib-receiving member integral to the inner surface of the at least one member, wherein the rib-receiving member comprises at least one rib-receiving element having an opening therein for receiving the first end of the rib and at least one cover sheet having an opening therein for receiving the first end of the rib.

Abstract: A machine and method for corrugating a metal foil strip utilizes an enclosure defining a chamber and a controllable heat source for heating the chamber. The chamber may optionally include at least one gas that is also heated by the heat source. At least one tool set received in the chamber forms corrugations in the metal foil strip. Foil entry feeder elements supply and guide the metal foil strip from outside the chamber into the chamber and to the tool set. A drive for the tool set is mounted outside the chamber and coupled to the tool set to actuate the tool set. Foil exit delivery elements guide the strip from the tool set and out of the chamber. Where required to prevent oxidation of the foil strip, a source supplying an inert gas to the chamber at a controlled rate is used.

Abstract: A machine and method for corrugating a metal foil strip utilizes an enclosure defining a chamber and a controllable heat source for heating the chamber. The chamber may optionally include at least one gas that is also heated by the heat source. At least one tool set received in the chamber forms corrugations in the metal foil strip. Foil entry feeder elements supply and guide the metal foil strip from outside the chamber into the chamber and to the tool set. A drive for the tool set is mounted outside the chamber and coupled to the tool set to actuate the tool set. Foil exit delivery elements guide the strip from the tool set and out of the chamber. Where required to prevent oxidation of the foil strip, a source supplying an inert gas to the chamber at a controlled rate is used.

Abstract: A machine for corrugating a metal foil strip includes a form gear having identical cavities along its perimeter that is driven intermittently by an electronically controlled rotary servomotor to index successive cavities to a forming station. During each dwell of the form gear, a form tooth of a punch unit at the forming station is driven by an electronically-controlled linear servomotor into the cavity to at least partly form a corrugation in the strip. During each operating stroke of the punch unit, a hold finger clamps the immediately outgoing node of the corrugation that just left the forming station against the immediately outgoing tooth of the form gear, thus preventing any part of the outgoing corrugation from being pulled back into the cavity and ensuring that the next corrugation is formed solely from a segment drawn in from the incoming foil.

Abstract: A light weight composite layer arrangement for providing protection for a metal surface from a fire for a predetermined period of time in compliance with Federal Airworthiness Regulation 25. The arrangement which may be easily installed on a metal surface, which typically is an aluminum alloy, includes a silicone rubber sealant layer that is applied to the metal surface in an uncured non-flowing state. A layer of ceramic fiber fabric is then applied to the first silicone rubber sealant layer and due to its inherent flexibility easily conforms to the contours of the underlying metal surface. A second silicone rubber sealant layer may then be applied in its uncured non-flowing state over the ceramic fiber layer to essentially embed the ceramic fabric layer between the two silicone rubber layers. The silicone rubber sealant layers may then be cured at room temperature.