Abstract: The invention relates to a multi-layer composite plates and to a method for producing multi-layer composite plates. Said multi-layer composite plates are comprised of two outer metallic slabs which serve as top and base plates and which are joined to a deformable connecting material located therebetween. The top and base plates are joined to the connecting material by means of a foaming adhesive which fills the cavities remaining in the composite. The cavities remaining in the composite are completely or partially filled by the adhesive. According to the method for producing multi-layer composite plates, adhesive is introduced between the layers to be joined, and the adhesive is subjected to a thermal treatment. The adhesive is completely or partially hardened during the thermal treatment. In the case of the partially hardened adhesive, the adhesive is completely hardened during an additional thermal treatment only after the multi-layer composite plate is reshaped.

Abstract: A stack assemblage of metallic, paper, or paper-like sheets or strips of material secured to one another to define a honeycomb core structure when the assemblage is expanded and flange tabs provided on the opposite edges of said stack. When the stack is expanded, the flange tabs can be deformed into flange orientation on the opposite edges of said stack. The method of fabricating the flange tabs and flanges on the assemblage and the expanded core structure.

Abstract: A building panel constructed of a gypsum-cement-catalyst formulation molded in layers and including a rigid stud framework. The layers include surface layers, a fire resistant layer and an insulating layer, as well as reinforcement and building paper. A modified panel is molded in layers with structural strength provided by a grid providing spaced apart wire panels.

Abstract: A method for forming the edge profile of a decorative laminate panel, wherein the decorative laminate panel includes a decorative surfacing layer, a backing layer and a substrate positioned between the decorative surfacing layer and the backing layer. The method is achieved by creating a recess defined by the decorative surfacing layer and the backing layer, forming an edge member shaped and dimensioned for placement within the recess, the edge member including an interlocking profile, and positioning the edge member within the recess with the interlocking profile exposed for selective attachment to adjacent laminate panels. The invention further relates to a laminate panel manufactured by the method described above. In addition, the invention relates to a connecting system for coupling adjacent panels. The connecting system employs a track locking strip in securely coupling the panels in accordance with the present invention.

Abstract: A plurality of thermoplastic tubular segments having substantially equal lengths are arranged in horizontal side-by-side relationship with the respective ends of the tubular segments aligned in a generally common plane. Small portions of the respective ends of the tubes are cut by a thermal cutting device which simultaneously fuses the ends of the tubes to produce a consolidated unitary structure having a thickness defined by the distance between the fused ends of the tubular segments. The consolidated unitary structure is then rotated to a horizontal position, with the tubular segments vertically oriented, and cut along at least one horizontal plane to produce fused cores having a thickness defined by the vertical position of a horizontally disposed thermal cutting device.

Abstract: Apparatus and a method for assembly of panels into a composite structure are provided. The structure includes a form jig (1) having form boards (3, 4, 5) defining forming edges (6, 7, 8) against which a composite panel to be precisely formed may be drawn by a number of edge clamps (12), usually in combination with suction devices (26, 27, 28, 29, 30). The edge clamps (12) are able to extend around edges of the panel (13) for initial location of the panel against the form boards and subsequent more powerful drawing action to draw the panel into intimate contact with the forming edges of the form boards.

Abstract: Core-type structures are formed by extruding elongated tubular members or sheets of a thermoplastic material that are subsequently cut into segments or plates having a defined length and then assembled into a bundle. The bundle is then simultaneously cut at a number of spaced-apart locations along the length of the bundled segments, or plates, whereby a plurality of separate core structures are simultaneously formed.

Abstract: The present invention relates to solid panel window shutters having both high strength and structural stability. More particularly, an exterior window shutter made of a solid panel of polyvinyl chloride with at least one support member affixed in the panel. The shutter includes a solid panel having front and back surfaces and side edges, support member, impact resistant member and slats having a channel to receive the support member; wherein the support member is embedded between the panel and the slats. Also contemplated by this invention are: a method to manufacture high strength and structurally stable exterior window shutters and a method to protect windows from extreme weather.

Abstract: A forge/swage formed three dimensional multilayer metal foil shield having areas therein where the layers are in a spaced apart relationship, areas therein where the layers are tensioned or stretched, and areas therein where the layers are compressed and interlocked together by folding, rolling, wrinkling, curling, coiling, crimping and the like. The multilayer metal foil shield is formed by forge/swage shaping in an appropriate mold apparatus a preform of a stack of metal foil layers having gaps between the layers. The gaps are provided by embossments in the layers or by spacers between the layers. The forge formed multilayer metal foil shields have utility as heat shields and acoustic shields, particularly on vehicles. The forge formed multilayer metal foil shields are mounted on automobile underbody areas, such as the bottom of the floor pan of the passenger compartment, to provide heat and sound insulation. Other automotive uses include fire wall, exhaust tunnel, motor mount and exhaust down pipe.

Abstract: A method of fabricating an aircraft leading edge nose structure includes the following steps. Parallel strengthening members are welded onto a flat planar outer skin sheet. Two forming tool members having appropriately shaped outer contours contact the inner surfaces of the strengthening members, and are then pivoted and shifted toward each other so as to bend the outer skin sheet into a parabolic shape along the curved contour defined by the forming tool members. The resulting bent outer skin sheet with the strengthening members welded thereon is secured into a negative mold. To provide boundary layer suction, a perforated throttling sheet, inner ribs, and a non-perforated inner skin sheet may be successively secured by sealant and blind rivets onto the pre-bent structure of the outer skin sheet and the strengthening members. The finished structure is then removed from the mold.

Abstract: The object of the invention is a process for the production of a panel with a protective acoustic damping layer, comprising at least one porous core covered, on the one side, with a porous acoustic damping layer (10) and on the other side with a total acoustic reflector, in which at least one said porous layer (10) is emplaced by striping or draping, said porous layer (10) being constituted of parallel strips (13), characterized in that the edges (15) of the strips (13) of the porous layer (10) are positioned facing a strip (16) deposited by striping or draping and containing a thermoplastic, thermosetting or thermofusible material adapted, by subsequent heating, to ensure the securement of the edges of said strips (13) with the adjacent strip (16).

Abstract: An integral metal spacer for insulated glass units and method of fabricating the spacer. The spacer defines a substantially closed cross-section contour having a bottom surface, a pair of sidewalls, and a pair of generally abutting inner surfaces. A gap may be defined between the adjacent inner surfaces. The three interior corners are defined by fully mitered sidewalls. A pair of bridges are provided to integrally interconnect the inner surfaces of adjacent spacer segments. The method of fabricating includes taking a roll of flat metal stock and completely punching all corner and other structures therein while the stock is planar; severing the punched stock into individual spacer members; roll-forming the individual members into a finished linear spacer piece; applying desiccant during roll-forming; applying sealant; thereafter folding the elongate member into a square spacer thereby locking the desiccant therein.

Abstract: A building panel constructed of a gypsum-cement-catalyst formulation molded in layers and including a rigid stud framework. The layers include surface layers, a fire resistant layer and an insulating layer, as well as reinforcement and building paper. A modified panel is molded in layers with structural strength provided by a grid providing spaced apart wire panels.

Abstract: An integral metal spacer for insulated glass units and method of fabricating the spacer. The spacer defines a substantially closed cross-section contour having a bottom surface, a pair of sidewalls, and a pair of generally abutting inner surfaces. A gap may be defined between the adjacent inner surfaces. The three interior corners are defined by fully mitered sidewalls. A pair of bridges are provided to integrally interconnect the inner surfaces of adjacent spacer segments. The method of fabricating includes taking a roll of flat metal stock and completely punching all corner and other structures therein while the stock is planar; severing the punched stock into individual spacer members; roll-forming the individual members into a finished linear spacer piece; applying desiccant during roll-forming; applying sealant; thereafter folding the elongate member into a square spacer thereby locking the desiccant therein.

Abstract: A door comprising two metal panels and an internal core structure. The panels have their edges formed around a perimeter sub-frame of channel construction, the base of the channel being internally adjacent the respective edge of the door. Opposing edges of the panels are seam welded together to provide a flush finish, and the base of the channel is apertured to act as a heat sink and to allow weld gas to escape.

Abstract: A flexible fixture system and method wherein a single fixture system can accommodate and hold a plurality of different workpieces, i.e. the various workpieces comprising the different flight surfaces of a wing. The flexible fixture system comprises a plurality of posts each including a plurality of different contoured formers, one former for each of the different workpieces to be accommodated and held by the flexible fixture system. Depending upon which workpiece is to be held by the fixture system, the required former on each post is selected automatically and moved into position for operative association with the workpiece. The contoured formers include powered clamps for holding details to be fastened to the workpiece. Each post of the flexible fixture system also includes a plurality of holding devices, such as suction cup type devices, which are moved into position to hold the workpiece and maintain its curvature.

Abstract: A method of forming a prefabricated insulated wall panel for installation with like wall panels for easily and inexpensively building a wall.

Abstract: A method of manufacturing a concrete deck form panel includes the initial step of cutting an insert within the panel, which may be removed by sliding the insert longitudinally from the panel. A pair of structural members are attached to the longitudinal sides of the insert, and then the insert is returned to the original position within the panel. A series of panels are connected to form a floor for supporting concrete, thereby forming a concrete deck system. In a second embodiment of the invention each form panel is formed by attaching a pair of structural members to longitudinal sides of a central body and then attaching L-shaped members to the structural members. A top plate is mounted to the top of the L-shaped members and the central body to form the integrated form panel.

Abstract: The present invention provides a bracket for the ease of installing cables in or on a partition wall, wherein the bracket is comprised of a base member for mounting onto the frame of the partition wall, and for providing a means to support cables laid onto said bracket. The back portion of the base member is provided with partition wall mounting means (e.g, hooks), for mounting the bracket onto a partition wall frame. The front portion of the base member is provided for laying onto and supporting the cables that have been laid onto the bracket. A hinge portion is provided at one end of the base member to provide for pivotal movement with the base member. Preferred embodiments provide for either a separate member or integrally fabricated member which is pivotally connected to the base member at the hinge portion. Such separate or integral member may be adapted to engage a partition panel cover or as a bracket cover member.

Abstract: A method for using a support backer board system and siding. The support backer board system comprises at least a first layer. The first layer is made from a material selected from the group consisting of alkenyl aromatic polymers, polyolefins, polyethylene terephthalate, polyesters, and combinations thereof. The board system is thermoformed into a desired shape with the desired shape being generally contour to the selected siding. The siding is attached to the board system so as to provide support thereto. In one process, the siding may be vinyl.

Abstract: A titanium honeycomb 1 is manufactured by using titanium or titanium alloy as the base material 2, performing diffusion bonding in a striped pattern with heating and pressing, and elongating the stacked base materials 2 . Further, a powder of rare earth oxide, such as yttrium oxide with a particle size of, for example, 30 &mgr;m or less, is employed as the parting agent 5. The oxide is mixed in an amount of 1% by weight or more with the organic binder vaporizing at 350° C. A parting agent is applied at a thickness of 0.3-30 &mgr;m.

Abstract: A prefabricated insulated wall panel for installation with like wall panels for easily and inexpensively building a wall. The wall panel is a unitary combination of (1) a member having a planar portion and a plurality of spaced rib portions integral therewith and extending therefrom for receiving insulation therebetween, (2) insulating material attached to edges of the rib portions for reducing thermal conductivity from the rib portions to wallboard attached to the wall panel, and (3) a nailer for attachment of wallboard.

Abstract: A building panel constructed of a gypsum-cement-catalyst formulation molded in layers and including a rigid stud framework. The layers include surface layers, a fire resistant layer and an insulating layer, as well as reinforcement and building paper. A modified panel is molded in layers with structural strength provided by a grid providing spaced apart wire panels. The panel is constructed by a method that includes applying a fluid material of gypsum and cement into a mold having a removable base. Reinforcing mesh and a rigid framework are inserted into the mold along with building paper and reinforcement which are secured to the framework. Additional gypsum and cement are then applied to cover the framework after setting. The base is removed and the initial layer of gypsum and cement is mechanically fastened to the framework.

Abstract: A wall panel including a rectangular frame, a pair of wall members and a thin decorative sheet covering the wall members. The frame includes two spaced apart, generally parallel vertical frame members and spaced apart, generally parallel horizontal lower and upper frame members. The horizontal frame members are connected to the vertical frame members at opposite ends thereof to form the rectangular frame. Each of the frame members includes a core member and a pair of sidewall members attached to opposite sides of the core member. The wall members are attached to the sidewalls on opposing sides of the frame members. A decorative sheet covers the outer surface of each wall member. A method for manufacturing the frame members includes providing a fixture with spaced apart first, second and third surfaces. A hanger bracket is mounted to the vertical frame core member and is positioned in the fixture such that the hanger bracket engages the first surface.

Abstract: A method for producing a polymeric foamed material panel including the steps of providing a polymeric foamed material; and cutting (e.g. hot wire cutting) the polymeric foamed material until reaching a preconfiguration cut point. The method further includes cutting subsequently from the preconfiguration cut point a brace-receiving configuration in the polymeric foamed material; and sliding a brace member into the brace-receiving configuration to produce a polymeric foamed material panel. A method for forming a structure comprising engaging together a pair of polymeric foamed material panels produced in accordance with the method for producing a polymeric foamed material panel. A polymeric foamed material panel comprising a panel consisting of a polymeric foamed material, and a brace-receiving-configured slot disposed in the polymeric foamed material of the panel. A brace member is disposed in the brace-receiving-configured slot in the polymeric foamed material of the panel.