Abstract: A method and product for repairing a sound attenuation structure for aircraft jet engine noise that includes a central honeycomb core having an imperforate facing sheet adhesively bonded thereto and a perforated facing sheet adhesively bonded to the opposing surface of the core with a woven wire cloth media adhesively bonded to the outer surface of the perforated sheet. The wire cloth is subject to deterioration and disbonding in service use. The method provides for the removal of the deteriorated wire cloth that has disbanded or deteriorated and, after cleaning of the perforated sheet and the associated honeycomb core area, and priming of the cleaned area of the perforated sheet replacement with a polymer film that is precoated with a pressure sensitive adhesive so that the film may be easily applied to the exposed perforated sheet area in place of the removed wire cloth.

Abstract: A hollow structural component which includes an integral structure, partition walls intersecting each other within the integral structure, and a plurality of independent hollow portions formed as specified by the partition walls so as to be arranged within the integral structure. The integral structure is formed into one piece by one-shot molding or by one injection molding die which is caused to slide against each other between its stationary side and movable side for post-forming, whereby weight reduction of the hollow structural component, reduction in the amount of resin used, reduction in the number of parts involved, and improvement in the workability for assembling may be achieved with consequent cost reduction.

Abstract: A hollow structural component which includes an integral structure, partition walls intersecting each other within the integral structure, and a plurality of independent hollow portions formed as specified by the partition walls so as to be arranged within the integral structure. The integral structure is formed into one piece by one-shot molding or by one injection molding die which is caused to slide against each other between its stationary side and movable side for post-forming, whereby weight reduction of the hollow structural component, reduction in the amount of resin used, reduction in the number of parts involved, and improvement in the workability for assembling may be achieved with consequent cost reduction.

Abstract: Methods and apparatus for forming honeycomb structure from a plurality of substrate layers. The layers are bonded together by spaced, parallel, solid node strips of thermoplastic material pressed and heated above the softening temperature to bond to the substrate surfaces and form a block. After cooling, the block is expanded into a honeycomb structure. Alternatively, the solid node strips can be placed on the spaced raised crests of corrugated layers of substrate, and successive layers bonded together by pressure and sufficient heat between the crests of one layer and the corresponding depression of the successive layer, to elevate the node strips above the softening temperature. Several alternative methods and apparatuses for achieving the result are disclosed.

Abstract: Method of producing metal sheets or strips by cold reduction rolling of a metal sheet or strip with at least one pair of work rolls, at least one of which being a textured work roll in order to transfer the surface pattern of the textured work roll to the surface of said sheet or strip, characterized in that said pattern of the textured work roll consists in a bidimensional deterministic pattern of spots wherein each spot has the form of a crater with a rim around it.

Abstract: A composite web structure utilizing a thin first layer of material having a plurality of structural fibers arranged to lie essentially in a unidirectional orientation. A thin second layer of material is positioned adjacent the first layer and includes a plurality of structural fibers. First and second layers are impregnated with a matrix material for binding fibers within the first and second layers and for binding the first and second layers together. The web may be formed into a composite structure such as a honeycomb core for fabrication into a panel.

Abstract: An improved panel structure wherein at least one face of the panel is perforated with small holes and where it is desirable to minimize the number of holes that get filled in with adhesive. For example, an improved noise reducing acoustic panel (30) (FIG. 3) constructed of a nonperforated inner skin (14), a perforated outer skin (16) having small holes (18), two sections (12, 12a) of honeycomb core material which are bonded or spliced together by a partially or fully encapsulated foaming adhesive (32e) which has been foamed and expanded, thereby forcing a supported film adhesive (34c) against the walls (24, 24a) of the honeycomb cells in the area of the gap (22) whereby the supported film adhesive (34c) bonds to the walls (24, 24a) of the honeycomb cells in the area of the gap (22). The nonperforated inner skin (14) has been adhesively bonded by a film adhesive to the honeycomb core sections (12, 12a).

Abstract: A syntactic structural foam product in flat sheet form or curved three-dimensional form adaptable to such uses as a light weight structural core for composite laminates, is made of a mixture of hollow ceramic microspheres and dry resin powder, of either thermosetting or a high-temperature thermoplastic resin, distributed in the interstices of the mass of microspheres for integration of the mixture into desired form upon heating and cooling. The dry resin powder in another embodiment of the invention includes unexpanded expandable powder which will expand into microballoons in the confined spaces in which they reside and effect a bonding relation with surrounding particles upon supply of heat to the mixture. The foam product is produced by thoroughly intermixing and depositing the mixture as a layer over a surface having a release agent thereover within a dimension defined region.

Abstract: The invention relates to a hollow fibre-reinforced plastic body comprising a curable resin-impregnated winding of high-strength fibres. To provide a strong hollow fibre-reinforced plastic body having a quick-to-make wall thickness the invention proposes that a double-walled shell which surrounds the hollow body interior is made by a first winding of one or more tapes of an uncut double pile cloth having a spaced-apart top cloth and bottom cloth and also binding pile threads which is covered by an outer winding, the windings being impregnated with a curable resin.

Abstract: A ceramic composite is provided comprising ceramic fibers, glass microballoons and/or diatoms, bound together with a ceramic reinforcing cloth with a sol-gel ceramic binder. The composite is particularly useful as a high strength, high temperature insulation material.

Abstract: A catalytic converter substrate comprising: a plurality of cell groups, each cell group comprising a plurality of air-flow cells extending axially through the substrate, each cell group comprising a first set of walls defining a radially outer periphery thereof and a second set of walls suspended by the first set of walls partitioning the individual air-flow cells from each other, wherein the first set of walls has a first effective thermal mass and the second set of walls has a second effective thermal mass, wherein the first effective thermal mass is greater than the second effective thermal mass.

Abstract: A former for use in a core sandwich of composite reinforced plastics material, the former comprising a rib section (5) divided into a plurality of sub-sections (8) by slits or openings (10) extending partway through said rib section (5) to define a hinge or web section (11) between each adjacent sub-section. A sheet former (22) may be produced by a number of parallel rib sections (5) each joined to adjacent rib sections by a flexible bridge portion (20) to define openings (25) in the former between each bridge portion (20) and the rib sections (5) and/or sub-sections (8). Venting between the sub-sections (8) may be provided by a venting channel (21) formed in the bridge portion (20). An array of upstanding formations (30) each joined at their base 31 by a flexible bridge portion (20) to produce a former sheet (22) is also disclosed. The bridge portion (20) allows venting between these formations through a channel (21) and allows bonding through openings (25) in the sheet (22).

Abstract: Sandwich construction building materials are produced using conventional facings of plywood, fiberboard, particle board, mineral board, wood, metal, plastic, etc. on both faces of the building material, the inner core therebetween being made from natural wood veneer, made from wood fibers or wood shavings combined with synthetic resin, bamboo, etc. bent into elongate strips of angular, corrugated or undulating configuration or rolled into hollow tubes. The strips or tubes may be cut transversely into strips of rings of equal height and assembled proximately of contiguously to form an inner core layer having an openwork pattern. Openwork spaces may be filled with insulation or strengthening materials, and core elements may be coated with resins or adhesives. The resulting building products may be modular and lightweight, strong and suitable for use as plywood, flooring, walls, beams, joists, trusses and posts.

Abstract: A honeycomb material is disclosed whose walls are formed from a network of a porous fiber composite, said composite being a reinforcing yarn embedded in a resin matrix.

Abstract: The invention includes a ceramic catalytic converter substrate having cell walls with rounded corners. The cell walls have a honeycomb or hexagonal shape with rounded corners. The cell walls may be manufactured with very thin walls from 0.003-0.005 inches. There is provided increased structural strength of the substrate due to rounded corners of cell walls into honeycomb or hexagonal shaped walls. The rounded corners of the cell walls also substantially increases the strength of the substrate. The honeycomb shape of the substrate uniformly dissipates any force applied to the substrate. The rounded corner cell walls allows a more uniform deposit of washcoat and precious metals and reduces the amount of precious metals necessary which coat the substrate along with reducing additional backpressure of the exhaust system caused by the washcoat which normally forms fillets in corners of squared-celled substrates.

Abstract: A cellular pleated shade material is provided for cellular pleated shades. Each pleat thereof is formed from a single strip of shade material which is folded longitudinally in half, and the edges thereof are glued together to form a fin. The side of one cell is affixed to the side of the next adjacent cell adjacent the centerline of the sides. The ratio of cell height to cell width may be varied, without affecting the overall aesthetic presentation of the shade, by varying the size of the fin.

Abstract: A decorative emblem for a vehicle comprises an oval bezel and a transparent lens. A groove with an angled sidewall is formed in the top surface of the bezel. The sidewall forms an angle with the bottom wall of the groove between 88.degree.30' and 82.degree.30' around the oval bezel so that the sidewall overlies the bottom wall making the groove wider at its bottom than at its top to lock the lens in place. The lens covers the top surface and is formed thereon by pouring a liquid lens material on the top surface of the bezel filling the groove. The liquid lens material cures to a hardened condition and the angled sidewall locks the lens in position over the top surface. The lens is transparent so that colors and designs on the bezel are visible.

Abstract: A honeycomb structure (1) comprises a plurality of small tubes (2) bonded to each other along their sides. The small tubes (2) have a base body (4) made of a thermoplastic and which, at least on the outside, preferably on the outside and on the inside, carries a coating (5) made of an adhesively-active thermoplastic material. As a result of this coating (5), a good bonding of the small honeycomb tubes (2) to each other as well as to a cover layer (3) is possible.

Abstract: A method for manufacturing a woven packing used in a device having an internal structure divided in a plurality of chambers or channels connected to one another for realizing material transfer, heat exchange or fixing between gases, liquids or gas and liquid is disclosed. The packing forming the internal structure has undulating permeable sheets disposed in parallel to one another to form plural channels which extend substantially in the direction of a main stream of fluid, said sheets having projecting portions which are disposed in a direction crossing the direction of the main stream and joints being formed between adjacent permeable sheets in the projecting portions. The joints between the adjacent permeable sheets are formed by simultaneously weaving a plurality of channels to manufacture a woven packing.

Abstract: Methods and apparatus for forming honeycomb structure from a plurality of substrate layers. The layers are bonded together by spaced, parallel, solid node strips of thermoplastic material pressed and heated above the softening temperature to bond to the substrate surfaces and form a block. After cooling, the block is expanded into a honeycomb structure.Alternatively, the solid node strips can be placed on the spaced raised crests of corrugated layers of substrate, and successive layers bonded together by pressure and sufficient heat between the crests of one layer and the corresponding depression of the successive layer, to elevate the node strips above the softening temperature.Several alternative methods and apparatuses for achieving the result are disclosed.

Abstract: Process for the production of a composite sheet (90) comprising a cellular core (41) and at least one outer layer (42) by bonding the outer layer (42) to the cellular core (41), for example with the aid of an adhesive film (84) under pressure and at elevated temperature, where the adhesive film (84) may initially extend over the entire surface and breaks up in the region of the honeycomb interior under the action of heat and on exposure to a gaseous medium, concentrating at the points of contact between the cellular core (41) and the outer layer (42). The outer layer (42) itself has an adhesive layer or an adhesive film (83) on the side facing the cellular core. The outer layer bonds to the cellular core under pressure and at elevated temperature.

Abstract: A multi-layered, unbalanced, bonded sandwich panel having improved top load support capability per unit of weight is disclosed. The panel has a core, to the upper surface of which is affixed a multiple-ply top laminate. Similarly affixed to the lower surface of the core is a multiple-ply bottom laminate. The top laminate is thicker than the bottom laminate and supplies increased compressive resistance, while the bottom layer has an enhanced ability to withstand tensile forces. The core is preferably a honeycomb core, and unidirectional, fiberglass epoxy prepreg lamina are favored for each ply.

Abstract: A method for making a material with an artificial dielectric constant is carried out by choosing the desired dielectric constant for a particular electromagnetic field, selecting a substantially non-electrically conductive sheet material (2) from which the cellular core material (26) is to be made, applying an electrically conductive material (8) to selected areas on the sheet material and thereafter forming a cellular core material from layers of the sheet material having the conductive material already applied thereto.

Abstract: A method and apparatus for forming a honeycomb structure in which a plurality of thermoplastic layers are fused together at selected locations. The thermoplastic layers at each of the selected locations are melted together to form a welded portion which includes first and second exterior surfaces. The welding of the thermoplastic layers is controlled so that no more than one of the exterior surfaces is melted. This partial melting of one layer prevents undesirable welding to adjacent layers. An apparatus for carrying out the method for welding thermoplastic honeycomb structures is also disclosed.

Abstract: Disclosed is a core for use in a core-board, which consists of an embossed sheet of a light weight material comprising a central surface extending in a plane and a plurality of embossments called top and bottom cells, that are identical in shape and project from the central surface on both sides thereof. Each of the top and bottom cells is integral to the central surface and of pyramidal shape. Each of them also has an open base of regular hexagonal shape extending in the plane of this central surface and a top flat surface of regular hexagonal shape and of a smaller surface area than the base. These top and bottom cells are regularly distributed onto the central surface in such a manner that each top cell is not adjacent to another top cell but extends edge to edge to three spaced apart bottom cells, and each bottom cell is not adjacent to another bottom cell, but extends edge to edge to three spaced apart top cells.

Abstract: Resin flow into the cells of a honeycomb core in sandwich structures is eliminated by using an unsupported film adhesive, a barrier layer, and a scrim supported adhesive layer between the composite laminate and the core. Superior panels with lighter weights, improved mechanical properties, and more predictable structural performance result by keeping resin in the laminate rather than losing it to the core cells.

Abstract: A composite web structure utilizing a thin first layer of material having a plurality of structural fibers arranged to lie essentially in a unidirectional orientation. A thin second layer of material is positioned adjacent the first layer and includes a plurality of structural fibers. First and second layers are impregnated with a matrix material for binding fibers within the first and second layers and for binding the first and second layers together. The web may be formed into a composite structure such as a honeycomb core for fabrication into a panel.

Abstract: A honeycomb structure consists of a plurality of dual cell members, each of these members is formed of a continuous length of foldable material which is folded into a 8-figured configuration. The dual cell members are stacked and adhered superposedly to constitute a window covering and the like.

Abstract: Preimpregnated thermoplastic yarn is interwoven around spaced hex mandrels as weft members in a preformed ribbon, which may be folded into layers or cut into sheets for stacking in a honeycomb pattern in preparation for bonding. In block bonding, pressure and heat are applied to an entire fully stacked block to bond the interface facets together and form hex ducts around the mandrels, which must then be extracted, typically individually in a special pneumatic press process. In a preferred layer bonding process certain problems and limitations of block bonding are overcome by bonding each sheet as it is added to a stack buildup. An alternate layer bonding process is disclosed, which is facilitated by magnetic pressing, using electromagnets acting on ferrous mandrels to apply pressure evenly distributed along interfacial facets during thermal fusion bonding. The magnetically pressed layer bonding process is readily automated by disclosed apparatus. Heating and cooling are provided to the mandrels.

Abstract: Honeycomb materials having areas or volumes possessing different physical properties then the remainder of the honeycomb are prepared in a continuous process without requiring machining operations.

Abstract: A noise attenuation panel having a backing sheet, a facing sheet and a cellular core having a multiplicity of open-ended juxtaposed cells. The backing sheet extends across the ends of the cells at the rear of the core and the facing sheet extends across the ends of the cells at the front of the core. The facing sheet is made of a porous permeable thermoplastics material. The porous permeable thermoplastics material for the facing sheet is produced by powder sintering a thermoplastics material.

Abstract: A resilient prestressed honeycomb structure is disclosed in which at least one of its defined planar surfaces is cushioned along its lateral length by substantially continuously deforming it under compression to a preselected depth. Also disclosed is a one-step method for simultaneously cutting and forming a resilient prestressed paper honeycomb structure and apparatus therefor. One preferred embodiment of the resilient prestressed paper honeycomb structure is sufficiently strong and lightweight to use as an inner packaging for providing cushioning protection of articles having a fragility factor rating of less than about 85 G's against multiple impacts.

Abstract: A paper cushioning mat for packaging and a method of producing the paper cushioning mat. The paper cushioning mat comprises two paper substrates and multiple paper cushioning pieces distributed between the substrates and adhered thereto. The paper cushioning pieces are made by cutting a coil prepared by rolling a single faced corrugated fiberboard and fixing with an adhesive crosswise to round slices of a certain thickness. Angle of cutting the coil may be inclined to the angle rectangular to the axis of the coil. The paper cushioning mat is used for packaging articles by, for example, laying the mat between the container walls and the article or by filling spaces. The mat can be reused, and easily disposed.

Abstract: The invention relates to a hollow fiber-reinforced plastic body comprising a curable resin-impregnated winding of high-strength fibers. To provide a strong hollow fiber-reinforced plastic body having a quick-to-make wall thickness the invention proposes that a double-walled shell which surrounds the hollow body interior is made by a first winding of one or more tapes of an uncut double pile cloth having a spaced-apart top cloth and bottom cloth and also binding pile threads which is covered by an outer winding, the windings being impregnated with a curable resin.

Abstract: A non-metallic honeycomb structure wherein the thermal conductivity of the structure is increased by incorporating high thermal conductivity pitch-based carbon fibers into the non-metallic resin matrix. In addition to increasing thermal conductivity, the pitch-based carbon fibers are utilized to provide controlled directional heat conductance through the honeycomb structure.

Abstract: A honeycomb sandwich panel modified by the controlled incursion of a foaming fiber-filled adhesive into the upper region of the honeycomb provides a panel having increased durability when the upper surface is subjected to localized compressive loads.

Abstract: A honeycomb-like regenerative bed element having an infinite number of cells, characterized in that the following formula is given:f=(1-.beta.).beta..sup.3wherein .beta. is an opening ratio of the regenerative bed element,.beta.=(P-T).sup.2 /P.sup.2P is a pitch of the cells, which is a distance between one center of gravity in one cell and another center of gravity in another cell, the distance extending across a common cell wall perpendicular thereto, andT is a thickness of wall of each of the cells, and that the P and T are set at a maximum value obtained by the formula f or set within a range of values close to that maximum value.P/T ratio, namely, a ratio between P and T may be set at 7.5 or within a range of values from 5 to 10 on the basis of the formula f so as to obtain an optimal conditions for the regenerative bed element.The regenerative bed element is formed from a ceramics material.

Abstract: In order to obtain a honeycomb structural body having excellent mechanical strength, which can eliminate a waste use of a catalyst, incomplete cells at an outermost peripheral portion of the honeycomb structural body are sealed selectively by ceramic materials. An incomplete cell does not have a square cross section if the complete cell has a square cross section, and is preferably defined by the cell having an area not more than 90% as that of the complete cell.

Abstract: A method of manufacturing a honeycomb structure of thermostructural composite material comprising a fiber reinforcing fabric densified by a matrix, the fibers of the reinforcing fabric being of a material selected from carbon and ceramics, as is the matrix, the method comprising the following steps:making a three-dimensional fiber fabric by means of superposed two-dimensional plies that are bonded together by means of fibers passing through the plies;making slit-shaped cuts in a staggered configuration through the plies, and through the entire thickness of the fabric;stretching the cut fabric in a direction that is not parallel to the cuts but that is parallel to the plies so as to form cells whose walls are constituted by the lips of the cuts; andwhile the cut texture is held in the stretched state, densifying it using the matrix-constituting material to obtain a rigid honeycomb structure of thermostructural material.

Abstract: A strainer for water outlet fittings which has multiple strainer apertures, which possess approximately equal open hexagonal aperture cross sections. The opposite surfaces of common side walls are approximately parallel to each other. The strainer is characterized by comparatively low noise, high throughput and at the same time good straining and cleaning action.

Abstract: A method of manufacturing a honeycomb table having a table leaf with apertures suitable for mounting components in sensitive applications, attaches a supporting section to that table leaf, attaches a sealing sheet to that supporting section, attaches a section of honeycomb core to that sealing sheet, and attaches a facing sheet at a position on the table such that the section of honeycomb core is positioned between the table leaf and that facing sheet. Apertures are drilled and tapped in the table leaf.

Abstract: The present invention pertains to a laminate material. The laminate material includes a first sheet and a second sheet spaced apart from one another by spacers to define a capillary zone for the capillary movement of fluid between the first and second sheets. The spacers connect the first sheet and the second sheet together to form the laminate material.

Abstract: Thermally conductive non-metallic honeycomb structures are provided as well as a novel co-corrugation process for their production. The thermal conductivity of the non-metallic honeycomb structures is increased by incorporating unidirectional thermally conductive fibers in the corrugated laminate sheets used to form the honeycomb. Thermally conductive fibers are integrated in the laminate sheets as a unidirectional fiber prepreg which minimizes the number of broken fibers and allows controlled directional heat conductance through the honeycomb structure.

Abstract: A package for preserving perishable food products such as produced shipped in large quantities on a pallet wherein the invention includes panels formed of honeycomb material covered by aluminum foil panels to provide a stronger and better insulated package.

Abstract: A process for fabricating panels of a core material with thermoplastic resin facings. The core material is either foam or a honeycomb structure from aramid paper. A belt press machine provides a means for rapid heating and cooling such that the core will not degrade. Since the process is so rapid, aramid fibers can be used to reinforce the resin facings without deleterious decomposition of the fibers under the temperatures used to heat the panels during forming.

Abstract: An improvement in a corrugated strip having major flat sections which extend between longitudinal edges of the strip and which are joined along lateral edges by intermediate sections extending between the major flat sections, includes stiffening ribs protruding from the strip along at least one of the connected lateral edges of the major flat and intermediate sections, the stiffening ribs being oriented substantially perpendicularly to the lateral edges. Additionally, a method and apparatus for forming corrugated strips, including corrugated strips having stiffening ribs, includes structure for applying a force, through dies, to a strip of material along an axis which is oriented at an acute angle to the strip.

Abstract: A non-metallic honeycomb structure wherein the thermal conductivity of the structure is increased by incorporating high thermal conductivity pitch-based carbon fibers into the non-metallic resin matrix. In addition to increasing thermal conductivity, the pitch-based carbon fibers are utilized to provide controlled directional heat conductance through the honeycomb structure. In one preferred embodiment, the pitch-based fibers are oriented to extend at an angle of plus or minus 55 to 60 degrees relative to the lengthwise direction of the honeycomb structure to provide optimum performance characteristics at a reduced cost.

Abstract: A non-metallic honeycomb structure wherein the thermal conductivity of the structure is increased by incorporating high thermal conductivity pitch-based carbon fibers into the non-metallic resin matrix. In addition to increasing thermal conductivity, the pitch-based carbon fibers are utilized to provide controlled directional heat conductance through the honeycomb structure. In a preferred exemplary embodiment, the cell walls are formed from a plurality of non-metallic unidirectional fabric layers, at least one of which consists essentially of unidirectionally oriented high thermal conductivity fibers.

Abstract: A combination of a thin upper honeycomb core plus a lower honeycomb core of equal or lower density than the upper core united by only a thin light weight interlayer within two outer skins provides a low weight hybrid panel with increased durability when the upper surface is subjected to localized compressive loads.