Abstract: Ski structure having good vibratory characteristics formed of a composite material including a core of light material for which the maximum allowable shear stress in the longitudinal direction and the maximum allowable vertical compression stress are, respectively, greater than 25 bars and 21 bars, the core being disposed between upper and lower working layers. The upper layer is constituted by a material whose modulus of elasticity in the longitudinal direction is less than 4,700 hbars. The material of the lower layer has a modulus of elasticity greater than 4,700 hbars. The product of the cross-sectional area and modulus of elasticity is between about 140,000 and 400,000 hbars mm.sup.2 for the upper layer, and between about 130,000 and 500,000 hbars mm.sup.2 for the lower layer.

Abstract: The present invention relates to a method for producing sandwich type structural components having a honeycomb core interposed between two cover layers. These cover layers are preferably made of fiber reinforced synthetic material. Force introduction points are formed in the structural components by insertion of a core filler mass in the form of a prepolymer which reacts to become a thermoplast. Force introducing connecting elements are connected to the force introducing points by melting these connecting elements into the core filler mass especially by using ultrasonic energy, for example, for an ultrasonic welding operation.

Abstract: A fire protection means comprises a panel consisting of a honeycomb core, having in cells thereof a fire-extinguishing fluid, and of facing sheets bonded to each face of the core, the panel being arranged so that, in use, it is more rigidly enclosed on one side than the other. On entry of, or impact with, a projectile, the facing sheet on the less rigidly enclosed side of the panel peels away, or otherwise preferentially breaks up or away, consequent upon passage of the projectile and/or the ensuing hydraulic shock, so that the fire-extinguishing fluid is rapidly liberated from a large proportion of the area of the panel and substantially in the preferred direction to suppress or extinguish rapidly any fire caused by entry of the projectile.

Abstract: An anvil having a working end away from a mounting shank, has compressed air flowing through the anvil to feed outward to the working end. An insert fastened to a panel is secured to the panel by forming on one end of the insert and by bonding with an adhesive on the other end. The working end of the anvil presses against the insert during forming and the flowing compressed air blows excess adhesive from the contacted surface of the insert.

Abstract: A laminated noise attenuation panel for both sound absorption and sound transmission loss having as its principal layers an expanded thermoplastic core with alternately inverted cavities, half opening to each side of said core and a sheet of cured resinous material having hollow microspheres with substantially reduced atmospheric pressure randomly dispersed in said resinous material, said cured resinous sheet facing away from the noise source. The cavities of said core panel facing away from said noise source may be filled with cellulose. The side of said core panel toward the noise source may include a laminated layer of a perforated material and a decorative layer. The side of said panel away from the noise source may also include a layer of other materials and a decorative layer. Data for the noise attenuation properties of various combinations of laminations are presented.

Abstract: A device for mitigating the splashing of droplets of molten metal during the pouring of same into a mould comprises a strip or strips of material which form a system of polygonal cells. The device is for vertical location with the strips edgewise in the base of a mould and fulfills the function of either a splash-guard when casting direct or a float when bottom-casting.

Abstract: A lightweight composite panel for use in constructing a portable or mobile enclosure capable of resisting penetration by small arms projectiles, explosive forces and heat having a multi-layered sandwiched construction. The layers include spaced apart metal panels with a honeycomb structure filled with a subliming material, a panel of projectile resisting material, and at least one panel of yieldable thermal insulation material disposed therebetween.

Abstract: A process for the preparation of composite laminate structures of glass cloth preimpregnated with polybismaleimide resin and adhered to a polybismaleimide-glass or aromatic polyamide paper honeycomb cell structure filled or partially filled with a syntactic foam consisting of a mixture of bismaleimide resin and carbon microballoons.The carbon microballoons are prepared by pyrolyzing phenolic microballoons and subsequently bonded using a 2% bismaleimide solution. The laminate structures are cured for two hours at 477.degree. K. and are adhered to the honeycomb bismaleimide adhesive using a pressure of 700 kN/m.sup.2 pressure at 450.degree. K. The laminate composite is then post-cured for two hours at 527.degree. K. to produce a composite laminate having a density in the range from about 95 kilograms per cubic meter to 130 kilograms per cubic meter.

Abstract: A non-combustible, abradable sealant composition for jet engines comprising a major amount of aluminum phosphate and a minor amount of silica or glass microspheres.

Abstract: Method is disclosed for preparing a honeycomb insulation structure having its cells partially filled with a low density foam and a high density integral skin completely covering one edge of the honeycomb. Method comprises placing one edge of a honeycomb in an inert material; introducing a foamable or foaming substance into the cells and allowing it to rise from the surface of the inert material until it overflows slightly. The overflowing foam comes into contact with a pressure platen just above the honeycomb thereby forming the high density integral skin. The level of the material in the cell determines the thickness of the void on one edge. Structure has utility in cryogenic storage.

Abstract: An aircraft control system component, such as a bellcrank, having sideplate members of three-ply laminates bonded together with an elastomer-modified epoxy, with the thickness of the central ply twice the thickness of the end plies, and with the outboard end ply being of selected thickness and yield strength so that when petalling occurs therein due to the passage of a projectile therethrough, the petals are deformable under control loads when they come in contact thereafter with associated parts to thereby permit the control system to continue to perform its function due to the improved ballistic tolerance of the component.

Abstract: A process for the preparation of composite laminate structures of glass cloth preimpregnated with polybismaleimide resin and adhered to a polybismaleimide glass or aromatic polyamide paper honeycomb cell structure filled or partially filled with a syntactic foam consisting of a mixture of bismaleimide resin and carbon microballoons.The carbon microballoons are prepared by pyrolyzing phenolic microballons and subsequently bonded using a 2% bismaleimide solution. The laminate structures are cured for two hours at 477.degree. K and are ahered to the honeycomb bismaleimide adhesive using a pressure of 700kN/m.sup.2 pressure at 450.degree. K. The laminate composite is then post-cured for two hours at 527.degree. K to produce a composite laminate having a density in the range from about 95 kilograms per cubic meter to 130 kilograms per cubic meter.

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 more 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 fiber-reinforced plastic structure is obtained by weaving fibers in one direction about one or more spacing members located angularly to the fibers. The fibers may be either warp or woof stands, the spacing member serving as woof when the fibers from warp strands, and as warp when the fibers form woof strands. The removal of the spacing member leaves relatively large open channels forming, in effect, a multi-wall hollow structure. The resultant structure may be partially or completely treated with a plastic resin system prior to or after the removal of some or all of the members. The solidified resin reinforced structure may be filled with a foam-in-place plastic, and it may be stacked in layers to provide additional thickness with reinforcing fibers running in different directions for additional strength. Some fibers may extend from one ply into an adjacent ply or into more remote plies.

Abstract: A plurality of shielded wires are held bundled and electrically interconnected at their braided-shield exteriors by a compacted metallic thin-wall honeycomb member whose collapsed cell walls encircle the wires individually. The honeycomb wrap around the wire bundle is encircled by a heat-shrunk sleeve of plastic tubing, and the collapsed cell walls are held electrically joined to the braided shields by conductive adhesive.

Abstract: Stiffened structural components, particularly integrally stiffened light weight shell structures, produced by molding astiffening member, preferably formed of a graphite-epoxy composition and having a so-called isogrid rib stiffening configuration, to a partially cured (B-stage) condition, injecting a suitable elastomer, e.g. a silicone, into the open spaces of the isogrid rib stiffener, to stabilize the partially cured composite during subsequent heat forming and curing operations, heat forming the resulting stiffening member to the required contour, e.g. for a cylinder into approximately 90.degree. arcuate isogrid panels, heat forming the skin of the shell structure by laying up a plurality of layers of a pre-impregnated tape within a cylindrical mold, installing a plurality, e.g.

Abstract: A flat honeycomb filler plate is provided with recesses to receive laminated, curable inserts. Flat top and bottom sides of the plate are covered by curable skins and a curable ribbon is wrapped around the narrow sides of that plate. The entire assembly is heat cured to obtain an intimate bond.

Abstract: A honeycomb-laminate composite structure comprisingA. a cellular core of a polyquinoxaline foam in a honeycomb structure, andB. a layer of a non-combustible fibrous material impregnated with a polyimide resin laminated on the cellular core,A process for producing the honeycomb-laminate composite structure and articles containing the honeycomb-laminate composite structure.

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 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 improved method of modifying a honeycombed body having a multiplicity of open-ended cells extending therethrough between opposite face ends of the body to produce therein a multiplicity of flow paths for at least two and possibly three separate fluids. For accommodating two fluids, selected columns of cells within the honeycombed body are provided with openings near at least one face end for first fluid flow through one or two longitudinal, opposed boundary surfaces and through inner cell walls parallel to the cell axes while the open-ends of such columns on a face end perpendicular to the selected cell axes are sealed against fluid flow. Second fluid flow is through the unselected columns of cells parallel to and either in the direction of or counter to the first fluid flow. Specifically, the invention provides an improved method for sealing the selected columns of cells on face ends of the body.

Abstract: A heat exchange element, particularly suitable for use as a recuperator for external combustion engines, or a body for use as an afterburner or in filtration and osmosis, may be produced as a monolithic, ceramic, honeycombed body having a plurality of flow paths therethrough for two or three fluids wherein multiple flow paths of separate fluids are separated by walls which may be less than 10 mils thick.In a preferred method, a honeycombed ceramic body is provided with a plurality of open-ended cells extending from one face end to another face end and arranged in vertical columns of cells separated by vertical fluid barrier wall surfaces. Selected columns of open-ended cells are closed on both face ends of the body and entrance to and exit from the selected cells is provided by removing portions of cell walls near face ends of the body between fluid barrier wall surfaces.

Abstract: Metal, fiber or plastic panels are fabricated by the attachment of planar imperforate and/or partially perforated outer sheets to a specially formed center member comprising a web or sheet having a deformed surface defining an array of adjacent triangular projections and depressions. The center member is produced by the longitudinal cutting and folding of the web as it passes between two forming cylinders which mesh with one another, the cylinder peripheries carrying complementary arrays of spaced triangular-shaped tooth elements having their base lines aligned in the opposing cylinders, to shear and thereby relieve the passing web laterally so as to produce intermittent parallel cuts and angular folds in the web while gathering the web longitudinally thereby to form triangular, flat-topped cells in the center member. Instead of using two outer sheets, the formed center member can be used per se, e.g., as a packing medium, or it can be combined with only one outer sheet to form a single-face product.

Abstract: A double-skin building panel having an insulating core and having an outer facing sheet laterally offset from and spaced-apart from an inner facing sheet -- each panel presenting an overlapping edge portion along one longitudinal side and an overlapped edge portion along its opposite longitudinal side. The panels are adapted to be erected in lapped relation without externally visible fasteners. The insulating core comprises a honeycomb core member filling a major portion of the space between the facing sheets, and rigid spacing means, one positioned along each side of the panel and thermally insulating the facing sheets from each other. The honeycomb core member presents open ended cells which are substantially entirely filled with an insulating medium, for example, expanded silicate.

Abstract: A double-skin building panel having an insulating core and having an outer facing sheet laterally offset from and spaced-apart from an inner facing sheet--each panel presenting an overlapping edge portion along one longitudinal side and an overlapped edge portion along its opposite longitudinal side. The panels are adapted to be erected in lapped relation without externally visible fasteners. The insulating core comprises a honeycomb core member filling a major portion of the space between the facing sheets, and rigid spacing means, one positioned along each side of the panel and thermally insulating the facing sheets from each other. The honeycomb core member presents open ended cells which are substantially entirely filled with an insulating medium, for example, expanded silicate.

Abstract: An imperforate sheet of gasket material from which gaskets, for preventing leakage of fluid between opposed surfaces, can be made. The sheet, which may be produced by various methods, comprises a matrix of an elastically-compressible material and discrete volumes of substantially-rigid material so distributed therein that upon compressing the sheet between opposed surfaces, initially the matrix material solely resists compression and only thereafter do the discrete volumes also resist compression. The distribution is also such that the mean rate of compression over any area of the sheet is substantially the same as the mean rate of compression over another area of the sheet when the areas are similarly compressed. The discrete volumes form compression stops to resist undesirable over-compression of the sheet. Such a sheet has application in the automotive industry, gaskets made therefrom being particularly suitable for fluid-sealing in vehicle engines.

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 multi-ply woven article has elements positioned within pockets formed by double plies of the article to provide the article with desirable acoustical properties as well as considerable strength and rigidity. The double plies may comprise a generally parallel pair of rib plies which extend between the opposite faces of the article in generally zig zag fashion to form a plurality of intermediate rib portions, or a pair of generally parallel, spaced apart face plies forming each of the opposite faces of the article, or both. Some of the pockets formed by the double plies are filled with acoustical elements having a selected number of holes of appropriate size so as to pass sound waves therethrough at a controlled rate, while still other pockets are filled with non-acoustical elements which are generally impervious to sound waves.

Abstract: A multi-ply woven article has stiffening elements positioned within pockets formed by double plies of the article to provide the article with substantial strength and rigidity. The double plies may comprise a generally parallel pair of rib plies which extend between the opposite faces of the article in generally zig zag fashion to form a plurality of intermediate rib portions, or a pair of generally parallel, spaced apart face plies forming each of the opposite faces of the article, or both. The various stiffening elements may comprise one or more layers of relatively stiff material. The various layers comprising each stiffening element may comprise unidirectional fibers or materials oriented relative to the woven article so as to impart maximum strength in selected directions.

Abstract: A method for molding a silicone elastomer into a fiberglass honeycomb panel previously bonded to a face sheet panel. The elastomer is introduced into a mold under vacuum to prevent air entrapment, and the bonded honeycomb panel is positioned above the elastomer filled mold and forced into the elastomer for vacuum filling the honeycomb structure.

Abstract: A process is provided for the continuous production of a laminated product having a foam core between two substantially impermeable cover sheets one of which has longitudinally extending, transversely spaced inwardly directed recesses therein wherein a porous web is placed over the sheet having the recesses and a foamable liquid reaction mixture is poured over the web whereby only a part of the foamable reaction mixture passes through the web into the recesses.

Abstract: The invention relates to insulating elements particularly intended for use as a supporting core material in wall structures and the like, e.g. of the sandwich type. The insulating element consists of an insulating body of a non-supporting material such as mineral wool, which is intersected by a plurality of parallel, relatively thin sheet-formed bracing members of a stiffer material, such as polyester, polyethylene or the like, imparting to the element improved rigidity in one or more directions. The invention also relates to a beneficial method of producing such insulating elements, the method mainly comprising placing mats of the non-supporting insulating material in layers with intermediate coatings of the stiffer bracing material, and then cutting or dividing the assembled layers into slices with a thickness corresponding to the desired thickness of the insulation.

Abstract: A method of manufacturing foam filled laminated planks which includes continuous means for forming and feeding a longitudinally corrugated plastic reinforcing core between, and bonding it to, top and bottom cover sheet laminae consisting of roll-fed strips of resin-impregnated fabric. The corrugations of the core define channels extending lengthwise through the assembly consisting of the core and cover sheets, and lengths are cut off and fed laterally therefrom to a position wherein each channel is aligned with an elongated lance, and then fed longitudinally into overfitted relation on the lances. The outer ends of the channels are closed, and foaming plastic is fed into the channels through the lances. The planks are then moved off of the lances toward a desired delivery position.