Abstract: A curved honeycomb structural body having a number of through holes extending through the structural body along a direction in which the honeycomb structural body is curved. Thicknesses of interior walls defining through holes are set larger on a radially outer side of the curved portion than on a radially inner side thereof.

Abstract: A composite sandwich structure which includes upper and lower skin structures, first and second honeycomb core structures, and an intermediate portion disposed between the first and second honeycomb core structures. The intermediate portion comprises a composite laminate, a barrier member and a foaming adhesive layer disposed between the composite laminate and the barrier member. The foaming adhesive layer is of a type designed to expand when exposed to an elevated temperature. The composite laminate and the barrier member operate to limit the expansion of the foaming adhesive layer into the open cells of the first and second honeycomb core structures. The foaming adhesive layer, upon expansion, applies pressure against the composite laminate. This pressure, acting concomitantly with the applied curing pressure and the elevated temperature, cures the laminate. Furthermore, the expansion of the foaming adhesive urges the composite laminate and the barrier member apart so as to fill any core discrepancies, i.e.

Abstract: Disclosed is a lightweight honeycomb structure that comprises a top panel (34) and bottom panel (32) and a large-celled honeycomb layer (36) disposed between the top and bottom panels. The honeycomb panel structure according to the present invention can be used in such applications as a sound-absorbing payload shroud for launch vehicles, flooring and walls in aerospace applications, aircraft wings and in structures that will be exposed to high heat. Additionally, a method of making a honeycomb structure of thermoplastic material is disclosed.

Abstract: Film-based composite structures meet the requirements of highly weight-efficient SDI space-based systems. These structures are rigid, lightweight, dimensionally stable, and possess a high degree of structural damping. Thin-walled structures (wall thickness less than 50 .mu.) made from self-reinforced ordered-polymer films overcome drawbacks of fiber-reinforced composites, and provide resistance to microcracking, ply delamination and impact. They have high temperature capability (over 300.degree. C.), low temperature (cryogenic) capability and the capability for hardening and survivability. The modulus and dimensional stability of film-based ultralightweight honeycomb sandwich structures is better than currently possible with aluminum or fiber-reinforced composite materials. Other thin-walled structures such as tension web beams and thin facesheets also show similar stiffness-to-weight advantages over current materials.

Abstract: Cellular material formed from a plurality of component strips each comprising alternate ridge portions and groove portions interconnected by step portions, the step portions comprising a first riser, a second riser, and a furrowed step surface. The furrowed step surface has at least one indentation formed therein, preferably two oppositely-directed semicircular indentations. The resulting interconnected array of substantially identical cell units defines a sheet of cellular material exhibiting highly synclastic behavior. In an alternate embodiment, the step portion is replaced by a slope portion having at least one semicircular indentation formed therein. A method of fabrication of the novel cellular material is also provided.

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: 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 three-dimensional knit or woven fabric that is permeable to water vapor but impermeable to liquid water is provided. The fabric includes a first fabric layer, a second fabric layer and a yarn interconnecting the two layers. The two layers and the yarn are preferably made from a synthetic, such as a polyester or nylon. Both the first and second fabric layers have a barrier layer adhered to the outside surfaces thereof which is both impermeable to liquid water and permeable to water vapor. The fabric is imperviously sealed to prevent the infiltration of water.

Abstract: The invention describes a device for transporting materials which has at least a first pipe (I) and a second pipe (II), each having a six-cornered, honeycomb-shaped flow cross section, the first pipe (I) having at least two first wall parts (1) which are not arranged adjacent to one another and whose longitudinal edges (1') are arranged at a first distance (a) from the connection point (3) between the first wall part (1) and the adjacent second wall part (2), which connection point (3) is nearest to the longitudinal edge (1'). Plate-shaped brackets (4) are arranged at the sides of the first wall parts (1) remote of the materials to be transported at a second distance (c) from the nearest longitudinal edge (1'). The angle (.alpha.) of inclination between the plane of the bracket (4) and the plane of the first wall part (1) is 60.degree., and the second pipe (II) has at least one corresponding first wall part (1) which is arranged parallel to the second wall part (2) of the first pipe (I).

Abstract: An electrostatic separator is described which includes honeycomb collecting electrodes, which consist of star-shaped elements, wherein each star-shaped element consists of three wall parts (1, 2, 3), which are centrally joined and extend at an angle of 120.degree. to each other, at least one tube section (1', 2', 3', 5', 6') extends along the outer edge of each wall part, the tube sections (2', 5', 6') of any two adjacent star-shaped elements are arranged one over the other and adjacent star-shaped elements are connectted by a connecting rod (4), which extends in the tube sections (1', 2', 3', 5', 6') of at least two adjacent star-shaped elements.

Abstract: A continuous process for producing honeycomb support structures by bonding a plurality of thermoplastic sheets together. The process comprises feeding, aligning, supporting and bonding thermoplastic corrugated sheets in sequence to build a honeycomb-structure of the desired dimensions. Bonding is accomplished by impulse heating through retractable support bars in cooperation with a movable heating/cooling platen, pairs of sheets to be bonded being indexed therebetween, in sequence, to bond one sheet at a time to form the multi-sheet structure.

Abstract: A facing element (10) includes a honeycomb carrier plate (12) which is clamped, sandwich-like, between two cover plates (14, 16) by clamping anchors (18). On the upper cover plate (14) is affixed by adhesion, a natural stone plate (22). The honeycomb carrier plate (12) projects at two diagonal edges by projections (21, 23) beyond the cover plate (14). At both other edges of the carrier plate (12), pocket-like depressions (25, 27) are formed which, in form and position, are complementary to the projections (21, 23) at the diagonal plate edges. In the plate connection the projections of a facing element engage the pocket-like depressions (25, 27) of two adjacent facing elements so as to form a form-fit connection whereby a strong plate connection is created.

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: The core of a honeycomb panel consists of a set of corrugated strips each of which alternate abut the immediately adjacent strips. Interlocking protrusions are formed in the abutting portions of the strips. The protrusions provide automatic registration of the strips without jigging or fixturing. Preferably the protrusions are somewhat undercut to provide a detent or snapping action upon assembly to provide mechanical integrity prior to bonding. The snapping action also holds the abutting surface together for uniform bonding. Lateral registration of the strips can be provided by, for example, forming a lance and window or mating dimples in the abutting surfaces. Bonding of the abutting surfaces can be done by soldering, brazing, or gluing. This honeycomb core structure is suitable for the continuous fabrication of panels of arbitrary length, width, and thickness.

Abstract: An evaporative element or cartridge especially useful in humidifiers comprises a plurality of stacked slit and expanded wicking paper layers, and means for supporting the wicking paper. The supporting means may comprise a layer of slit and expanded metal sandwiched in between the stacked wicking paper layers. The stacked wicking paper and metal layers are held together with an adhesive. Alternatively, the supporting means may comprise a rigid frame on the side edges of the stacked wicking paper layers, the frame having prongs engaging the wicking paper layers. Each layer of stacked wicking paper is staggered with respect to adjoining layers. The wicking paper has superior capillary rise of 79 to 112 mm/min.

Abstract: There is disclosed an apparatus and method for forming a honeycomb core. In particular, the apparatus comprises a compressible array of heater rods that are interleaved with layers of a formable material. Upon compressing the array, the formable material conforms to the shape of the heater rods. Through the application of heat and pressure, the different layers of the formable material are caused to bind to each other. The bound layers thereby form a honeycomb core, which is then removed from the forming apparatus. Also disclosed herein are methods of making honeycomb core using the apparatus, as well as methods of determining precise curing conditions for the making of honeycomb core, by sensing the temperature and pressure transmitted to the formable materials during the curing process.

Abstract: High strength foam-filled materials and methods for their production are disclosed. The high strength materials include cellular structures comprising a plurality of open-ended cells containing polycyanurate foam. The polycyanurate foam-filled cellular structures have synergistically high mechanical properties and improved resistance to moisture. When cyanate ester foamable precursors in the form of tough films are foamed to fill honeycomb cells, the resulting foam-filled honeycomb has uniformly fine foam cell structure and improved bonding between the foam and the honeycomb.

Abstract: A flexible surface coating which promotes the removal of deposits as they reach the surface by preventing adhesion and crust formation. Flexible layers are attached to each side of a flexible mesh substrate comprising of a plurality of zones composed of one or more neighboring cells, each zone having a different compressibility than its adjacent zones. The substrate is composed of a mesh made of strands and open cells. The cells may be filled with foam. Studs or bearings may also be positioned in the cells to increase the variation in compressibility and thus the degree of flexing of the coating. Surface loading produces varying amounts of compression from point to point causing the coating to flex as deposits reach it, breaking up any hardening deposits before a continuous crust forms. Preferably one or more additional layers are also used, such as an outer layer of a non-stick material such as TEFLON, which may be pigmented, and an inner, adhesive layer to facilitate applying the coating to a surface.

Abstract: The present invention relates to a process for making a hexagonal-cell honeycomb core from a honeycomb half-cell structure. The structure has a plurality of peaks and valleys on each side thereof and a diagonal surface between each consecutive peak and valley. The process comprises the steps of applying a first adhesive component, which is preferably a cyanate ester and an epoxy, to a first group of peaks and applying a second adhesive component, which is preferably the epoxy and a catalyst, to a second group of peaks. The structure is then stacked so that the first adhesive component on the first group of peaks comes into contact with the second adhesive component on the second group of peaks, thereby mixing the components to bond the half-cell structure together and form the honeycomb core.

Abstract: An improved drawer dividing device comprising a plurality of strips of resilient material fixedly joined at a plurality of locations to form a collapsible grating which can be expanded, as required, to provide a desired number of individually separate storage spaces, yet which is adjustable in size to occupy only the amount of space required for storing the desired number of articles.

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: The invention relates to honeycomb core components having an undulating configuration reinforced with structural rods or columns which provide nesting sites for indexing with the flutes or nodes of adjacent components when assembled in stacked relation. Methods are also disclosed for producing the core components and assembling them in finished honeycomb core configuration.

Abstract: A structural or flexible highly insulative panel which may be translucent, is formed from multi-layer polymeric material in the form of an envelope surrounding a baffle. The baffle is designed so as to minimize heat transfer across the panel, by using material which forms substantially closed spaces to suppress convection of the low conductivity gas fill. At least a portion of the baffle carries a low emissivity surface for suppression of infrared radiation.

Abstract: Shaped honeycomb parts are prepared in a continuous process wherein webs of fiber-reinforced or non-reinforced thermoplastic are slit in a predetermined manner such that the finished honeycomb may be separated by hand into parts having a predetermined geometry.

Abstract: The invention relates to an insulative structure with both outwardly and inwardly facing aluminum foil layers supported by kraft paper layers which are, in turn, supported by a kraft paper honeycomb structure with walls perpendicular to the aluminum and kraft paper layers. The honeycomb structure includes a series of interlocking hexagonal compartments which support airspaces therewithin.

Abstract: An ornament set includes a plurality of ornament units having double-sided adhesive sheets adhered to the back thereof, and a retainer strip adhered to the front sides thereof to hold the ornament units in a predetermined relationship. A method for manufacturing the ornament set providing a plurality of ornament units respectively having front surfaces to be displayed and back surfaces to be attached to a body to be decorated, and providing an arranging tool having recesses formed therein in relative positions corresponding to relative positions in which the ornament units are to be attached to the body to be decorated. The ornament units are positioned in the recesses of the arranging tool, respectively, such that the front surfaces of the ornament units are respectively facing the bottoms of the recesses. A double-sided adhesive tape is adhered to the back surface of each of the ornament units, and a release strip is applied onto respective surfaces of the double-sided adhesive sheets.

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: An expandable collapsible product is made by providing a pleated sheet (8,10) having legs (20) which are made by securing two parts of a fold (17) together. Two sheets are combined by securing the end of a leg (20) to a crease (16) or a leg (20) of an opposite sheet. The sheet material is folded to preferably provide alternating taller folds (17) and shorter folds (16), and the taller folds are modified to provide the legs (20) by gluing parts of the taller folds (17) together. Gluing is accomplished by moving glue heads across the sheet at high velocity through the use of linear motors. The glue lines are heated after being laid down by the use of electro-magnetic radiation, preferably from a high-powered laser. The finished product is used as insulated window coverings, or the like.

Abstract: A gas capping liner system is described which encompasses a top channeled component and a bottom perforated layer component. The top channeled component has a plurality of alternating longitudinally extending channels. The channels are of two types, (1) structural for supporting the weight of overburden clay and topsoil above the liner and (2) gas-receiving, which permit the landfill gas to be collected. The perforated layer component is positioned such that the perforations are located above the gas-receiving channels.

Abstract: An improved reinforcing belt is provided for a pneumatic tire. In one embodiment, a composite belt is formed by bonding together a plurality of resin impregnated plies. Each ply is further formed from cords having a high extensional modulus of elasticity and a high tenacity which reinforce a matrix of semi-rigid resin. Preferably, the resin is cured or formed in situ during the curing of the tire in which the plies are placed. In another embodiment, a structural separator having a high resistance to compression is bonded to and between at least two of the plies.

Abstract: The composite comprises ceramic fiberformed insulation bonded to a fiber reinforced ceramic matrix laminate. Ceramic insulation has a mat of intersecting, discrete ceramic fibers bonded with a sol-gel glass binder. The insulation is prepared by forming a slurry of ceramic fibers, molding the slurry to form a soft felt mat, drying the mat, and incrementally introducing the binder into the mat with a multiple-impregnation technique, which controls shrinkage of the ceramic fiber mat. This process provides a layering technique that permits formation of a continuous fibrous structure having layers that impart distinct characteristics at desired regions within the structure. By using different ceramic fibers and fibers of differing physical dimension, or by including additives with the slurries, tailoring of the physical characteristics of the insulation is achieved.

Abstract: A sheet-like, foldable material is provided by laminating a very thin film-like veneer of material wood veneer to a thin backing material of paper or plastic by use of a bonding material which does not harden and can therefor be stretched and folded without causing rupture of the fibers of the wood veneer.

Abstract: A sound-absorbing multi-layer structure is disclosed comprising a structural part which is capable of oscillating and a loosely engaging damping sheet, which sheet comprises a flexible material and high material absorption factor and is made up of a heavy sheet with a viscoelastic support layer tightly connected thereto. The support layer comprises a plurality of angularly constructed support elements which are shaped and arranged so that together with the structure which can oscillate and the flexible heavy sheet they form a coherent labyrinth of hollow spaces with acoustically effective cavities.

Abstract: A very lightweight sandwich panel is constructed using as the core layer a very thin plastic sheet that has been preformed with projections having broad bonding areas on their free ends for chemically cementing to one outer layer of the panel and with areas between the projections for bonding to the other outer layer. The projections may be made of different cross-sectional shapes, heights, spacings, tilts, profiles, etc., to produce different characteristics in the panel. Differences may even be made in a given sheet to produce a panel having different characteristics in various portions, including shape and function. These characteristics can be predetermined, and the panels may therefore be computer designed. Special panel applications such as airplane wings and thermal boards are comtemplated.

Abstract: An expandable load spacer having a suspension strip fixedly attached to a generally honeycomb, cellular void filler is disclosed for use between stacks of articles of freight in, for example, rail cars and other shipping vehicles or containers. The load spacer substantially eliminates the hour glass effect generally experienced in suspended dunnage devices, while at the same time significantly reducing the amount of sheet material required in the manufacture of those load spacers.

Abstract: A body 20 includes a support structure 30 in which is formed monolithic aerogel 32 and has terminal insulating properties or other desirable properties. The body 20 can be enveloped in an impermeable membrane 34, 36 so as to allow a vacuum or another environment to be contained in the aerogel 32. The support structure 38 can include individual cells 22, each of which can support its own independent environment which is unaffected by the accidental or planned interruption in the environment of any adjacent cell 22.

Abstract: Fiber-reinforced thermoplastic honeycomb is prepared in a continuous manner one half cell at a time by laying down a corrugated web of thermoplastic, with and without fiber-reinforcement atop a honeycomb, selectively fusing the node-antinode demes and repeating the process until a honeycomb of the desired depth is prepared.

Abstract: A light weight honeycomb structure is disclosed made from aramid fibers and exhibiting extremely high shear modulus.

Abstract: Means for dampening vibrations in a strung game racket or a spoked wheel comprising a block of flexible, thermoplastic elastomer honeycomb bonded to and sandwiched between two thermoplastic facings. The device is inserted between at least two strings of the interwoven string diaphragm of the racket, or two spokes in a spoked wheel arrangement, in such a manner as to allow the exposed honeycomb core at the sides of the device to wrap around the engaged strings or spokes and hold the device in place. The device absorbs vibrations in the strings that originate from the striking surface when a ball is struck, and vibrations in the spokes emanating from normal use of a wheel.

Abstract: Ultra strong lightweight core material capable of sustained operation at unusually high temperatures for composite structure of the type used in aircraft parts such as wings, fairings and stabilizers is produced from preimpregnated thermoplastic fibercloth ribbon by the manufacturing processes of this invention. The fibercloth ribbon is preformed between corrugated rollers of a special roll forming press which heats the ribbon to a softening temperature, forms it into a pattern of half-hex corrugations, cools it and sets it in that pattern. Then sheets cut from the corrugated ribbon are stacked into a bonding press along with hex forming mandrels placed between the sheets in the corrugations.

Abstract: For producing ultra strong lightweight core material for composite structure such as aircraft wings, fairings and stabilizers, preimpregnated thermoplastic fiber yarn is processed according to this invention into blocks of ducted core material having a balanced honeycomb pattern. A tubular thermoplastic fabric sheath is braided along shaped mandrels, positioned end to end, as they pass through a braiding machine. The sheath is cut apart at the mandrel ends and the sheathed mandrels are stacked uniformly into a press, where the stack is compressed to contact all interfacial facets. Then heat is applied to fusion bond the stack together at the interfacial facets. Then after cooling to a setting temperature, the pressure is removed and the stack is removed from the press for mandrel extraction.

Abstract: Disclosed is a method and apparatus of molding laminated plates each comprising a honeycomb core sandwiched between two opposite reinforced resin sheets as skin layers. A molding surface is composed of a plurality of unit area of divisional sections, each having a heating layer embedded therein. A prepreg is used as the reinforced resin layers. The laminated plates are formed by putting the prepreg on a honeycomb material or a honeycomb material on a prepeg, and heating the laminate by a heating layer having nichrome wires. The same procedure is repeated to cover the other side of the honeycomb structure by another reinforced resin layer.

Abstract: A curved panel formed of joined corrugated strips with a series of crimps in one side of each strip so that the crimped side is shorter than the non-crimped side resulting in a curved strip which is joined to other such strips in a side-to-side fashion to form a curved core with honeycomb cells therein, and on which coverings are placed to form a panel.

Abstract: A shock absorbing filler for hollow sporting equipment that will absorb vibrations generated during use of said equipment. An elongated block of thermoplastic elastomeric honeycomb, either bare, singly faced or doubly faced, is packed within the hollow handle or hollow throat of an item of sporting equipment. The honeycomb block expands within said hollow core to provide a vibration dampening interface.

Abstract: A composite article, such as a telescope mirror blank, comprising a solid glass body and a supporting network structure, the structure being composed of a network of interlocking struts frit sealed to one another and to the face plate. The article is characterized in that sufficient of the glass body is incorporated in particulate form in the struts to maintain an average expansion mismatch (-50.degree. C. to +50.degree. C.) between the network structure and the glass body of no more than 0.15 ppm/.degree.C.

Abstract: A shock absorbing wrap for sporting equipment that will absorb vibrations felt by a player using said equipment as well as aid the players grip on the equipment. The wrap may be wound in an overlapping fashion and securely clamped in place or it may be adhered to the piece of equipment. The outer facing of the wrap can be perforated to provide a non-slip surface. Alternatively, the wrap can be used underneath a more traditional leather wrap.

Abstract: A multi-layered structural panel having a high-density cellular core adjacent and parallel to a low-density cellular core is disclosed. Preferably, the first core has a density at least 10% greater than the second core. The first panel preferably accounts for 10% to 25% of the structural material thickness.

Abstract: An improved expandable and contractible window covering comprising an assembly of elongated cells is disclosed. Each cell is formed by folding a strip of material and joining the opposed edges to the next adjacent cell. The rear wall of the cell is less wide than the front wall of the cell, and the material of the cell is chosen to be relatively soft and flexible, so that the front wall of each cell droops downwardly and outwardly away from the rear wall.

Abstract: The present disclosure describes a protective tarpaulin which protects military targets from detection and destruction by multiple weapon systems. The tarpaulin comprises a thermal protective sheet situated at its bottom surface in contact with the target it covers. A multi-cell honeycomb structure is disposed above and separated from the thermal protective sheet by a plurality of stiffeners. The tarpaulin also includes a temperature control means, in communication with an air gap defined by the space between the multi-cell honeycomb structure and the thermal protective sheet.

Abstract: A lightweight, high strength moldable structure is comprised of a core having a plurality of interconnected cavities. Each solid-walled cavity has a hexagonal base so that the core of the structure has upper and lower surfaces. Each solid-walled cavity has a unique tetrahexagonal shape in which a regular tetrahedron is located on top of and integrated with a hexagonal base. The walls of the cavities may be solid or they may be defined by a series of support struts for an even lighter weight structure. The upper and lower surfaces may be covered by skins, making it suitable for boat hulls, vacuum chambers, and aircraft.