Abstract: The invention is to perform operations from sealing of a honeycomb core with a thermosetting sealing material having an adhesive property to its hardening in one step, prevent a resin from flowing into cells of the honeycomb core during resin impregnating operation, and thereby mold low-cost honeycomb sandwich components by using RTM technique which is adopted in molding solid materials, for instance. Dry fabric sheets are stacked on both sides of a honeycomb core with thermosetting sealing members having an adhesive property placed in between, and the sealing members and the dry fabric sheets are heated at the curing temperature of the sealing members to cause initial hardening of the sealing members and to dry the dry fabric sheets. Then, the dry fabric sheets are impregnated with a thermosetting resin and the resin impregnated into the dry fabric sheets is hardened by hot-pressing an entire assembly thus prepared under specific conditions.

Abstract: The invention relates to a folded honeycomb structure and to a method and device for producing said folded honeycomb structure from a corrugated core web. The folded honeycomb structure has a number of adjacent corrugated core strips which lie in one plane and are interconnected by cover layer strips. Said cover layer strips are folded about 180° and are perpendicular to said plane. According to the inventive method for producing the folded honeycomb structure, interconnected corrugated core strips are produced first by making a number of longitudinal scores in a corrugated core web. These corrugated core strips are then alternately rotated through 90° respectively so that the cover layer strips fold and the folded honeycomb structure is formed. The device corresponding to this method consists of a number of rotating blades for making the longitudinal scores and a number of guiding elements for rotating the interconnecting corrugated core strips.

Abstract: A composite structural panel (10) is provided, where the composite structural panel (10) includes a central honeycomb layer (16) having a plurality of box-like channels extending therethrough along a vertical direction. The honeycomb layer (16) is sandwiched between bonding layers (18) formed from a porous reinforcement material. Exterior support layers (22) are bonded or laminated to respective bonding layers (18) by adhesive layers (20). The one-piece composite structural panel is then positioned on an exterior surface of a building (12) and structurally fixed to a building stud or other building element.

Abstract: A hollow core composite assembly 10 is provided, including a hollow core base 12 having an open core surface 14, a polyetherketoneketone film 22 applied to the hollow core base 12, and an adhesive layer 24 positioned between the polyetherketoneketone film 22 and the open core surface 14. The resultant hollow core composite assembly 10 can be cured to provide a structure suitable for use within a liquid molding process.

Abstract: A sandwich structure does not permit the permeation of water and a sandwich structure repairing method is capable of easily repairing the sandwich structure. A sandwich structure (1) includes a core (4) formed of a closed-cell foam plastic material, and surface plates (2, 3) formed of a fiber-reinforced composite material containing hydrophobic inorganic fibers as reinforcing fibers and bonded to the opposite surfaces of the core (4). Water is unable to permeate the sandwich structure.

Abstract: In order to manufacture a sandwich panel using the RTM technique, a stack comprising a core (10) with open cells, a film (12) of intumescent material covering each of the faces of the core (10), a dry barrier fabric (14) covering each of the films (12) and an overlay of dry fibers (16) covering each of the barrier fabrics is placed in a mold. During polymerization of the films (12), pressurization of the mold and the presence of the barrier fabrics (14) prevent penetration of the foam into the overlays (16). The resin is then injected into the mold and then polymerized, without danger of penetration into the cells of the core (10).

Abstract: The vented cell structure and fabrication method of the present invention provide an efficient and effective honeycomb structure that allows fluids to flow in and out of the honeycomb without any obstructions that may trap gases and/or liquid in the honeycomb cells. First and second honeycomb layers, including first and second cell walls, respectively, that define first and second cells, respectively, are positioned adjacent one another such that the first and second cells are misaligned. The first and second honeycomb layers are connected with adhesive only at intersections of the first and second cell walls to permit fluid to flow between the first and second cells without obstruction. A structural layer defining at least one opening aligned with the first and/or second cells is also applied on opposite sides of the first and second honeycomb layers, to thereby create the vented cell structure.

Abstract: The invention relates to laminated parts comprising outer layers and polyurethane sandwich materials, and to a method of producing these laminated parts and to their use in the automotive industry.

Abstract: A thermal insulator can change a heat insulation characteristic partially with a simple structure. The thermal insulator is divided into a plurality of parts in accordance with a temperature of a heat source which is insulated by the thermal insulator. The plurality of parts are formed of different honeycomb structures, respectively, so as to provide different heat insulation characteristics. The plurality of parts may be formed by different materials, or a shape or dimension such as a cell pitch of the honeycomb structure may be varied. Heat is collected from air within the honeycomb cells, and is transferred to other parts for heating.

Abstract: This invention relates to a novel composition suitable for use in the manufacture of electrophoretic display cells. The mechanical properties of the cells are significantly improved with this composition in which a rubber material is incorporated.

Abstract: A flexible sandwich panel (100), comprised of a center layer (1) and one or two outer layers (2; 3), where the center layer is made of a polymeric synthetic material, is itself flexible and exhibits a coarse-cell honeycomb structure with open cells (4) in the direction of the upper and lower side of the center layer. The outer layer or layers consist of a hardened mortar that is made flexible with synthetic additives, and that have as their core a web material consisting essentially of fibers, where the exterior side (5) of the hardened outer layer is left unrefined or roughcast in a plaster-like manner. The sandwich panel can be bent without flaking of the outer layers.

Abstract: In a honeycomb sandwich panel having a honeycomb core, and a front surface layer and a rear surface layer sandwiching the honeycomb core on its upper and lower surfaces, at least one of the front surface layer and the rear surface layer is made of a fiber reinforced plastic using a phenolic resin as a matrix.

Abstract: The present invention provides a vacuum heat-insulating block including a honeycomb core, wherein the block structure prevents the honeycomb core having a low bulk specific gravity from collapsing by atmospheric pressure, the block attaining flexibility and sound absorption property. The vacuum heat-insulating block 100 according to the present invention is basically composed of a core utilizing a plurality of layered honeycomb members 50 (formed by bonding a honeycomb core member 51 to a support plate 55) and covering the core with a cover member 70. Moreover, a woven or non-woven fabric 60 having air permeability is disposed between the layers of honeycomb core members 51.

Abstract: An extruded polycarbonate article suitable as an energy absorber is disclosed. The article includes a plurality of honeycomb chambers that are aligned substantially in the same direction, extend in the direction of the extrusion and are disposed adjacent to one another. A method of using the article entails aligning the honeycomb chambers in a direction parallel to the direction of the impact energy.

Abstract: A thermoplastic folded honeycomb structure and method for the production thereof A strip of material is plastically deformed perpendicular to the plane of the material and folded in the direction of conveyance until the cell walls meet and are joined.

Abstract: A method/apparatus closes and finishes an open end of a product that can be fused together with heat. The apparatus includes a bending stage, a fusing stage, and a pressing/cooling stage, which all can be integrally formed, with the bending stage positioned upstream of the fusing stage, and the pressing/cooling stage positioned downstream of the fusing stage. The apparatus can further include a trimming stage positioned upstream of the bending stage for preparing the ends of a panel. The product has a pair of spaced layers with edges that form an open end. Either one or both of the layers can be heated and rolled toward the other layer while being heated so that they contact and fuse together. The layers can overlap and fuse at their contact surfaces, or the edges can abut to form a butt joint, or the edges can overlap slightly.

Abstract: The invention relates to a component part, especially a rear parcel shelf, and to a method for the production thereof, whereby the component part is provided with a honeycomb-like core layer (2) which is provided with a reinforcing layer (3, 4) on each side. This layer comprises a nonwoven that contains thermoplastic fibers. The core layer (2) is made of thermoplastic material and is connected to the thermoplastic fibers of the reinforcing layer (3, 4) b material fit. The reinforcing layer (3, 4) is precompressed and air permeable and has an air flow resistance ranging from 500 Nsm−3<R<3500 Nsm−3.

Abstract: Honeycomb products and methods of manufacture thereof, particularly for aerospace applications. The honeycomb core products are made of a plastic material, such as a thermoplastic material, and preferably are made by a direct manufacturing process, such as stereo lithography, selective laser sintering, or fused deposition modeling. The cell sizes, shapes and wall thicknesses can be modified or varied throughout the product as desired. An interlocking structure is utilized to securely hold together adjacent honeycomb products.

Abstract: The honeycomb structure of the present invention is formed from a nonwoven fabric in which a biologically soluble fiber is used, and exhibits superior biological solubility and high heat resistance.

Abstract: A method and apparatus comprising combining ballistic and fragment resistant fabrics in multiple layers with a central geometrically shaped composite core in a resin forming a composite armor panel, wherein the multiple layers present a fragment projectile with alternating tougher and softer resistances to penetration to enhance the stopping power of the composite armor while retaining a lightweight configuration is disclosed. The panel allows the fabric layers and geometric core to interact in such a manner as to function as a drumskin, flexing and elastically deforming to absorb and attenuate the energy of a forced entry attack.

Abstract: A light diffusing insulating glazing insert consists of a flexible thin-walled honeycomb transparent insulation, to which is bonded a diffusing sheet, on one or both sides This provides a practical solution to problems related to utilizing thin-walled flexible honeycombs in glazing units consisting of two sheets of glass, plastic, or similar and a spacer/frame, as standard for window and skylight applications. Use of such a glazing insert adds insulation and light diffusion to the glazing system.

Abstract: An inorganic particulate, having strong absorption in the thermal infrared region of the radiative spectrum and low absorption in the solar or visible portion of the radiative spectrum, is combined with a plastic resin, to create a composite material. This composite is used in whole or in part to manufacture a honeycomb transparent insulation material, or is applied as a coating to a honeycomb transparent insulation material. The resulting honeycomb transparent insulation can have similar visible or solar light transmittance, and will have improved thermal radiant suppression relative to an identical honeycomb made of plastic resin only.

Abstract: A water-absorbent structure comprises an assembly of thermoplastic synthetic fibers, cellulose-based fibers, super-absorbent polymer and water-pervious sheets wrapping these components together. The assembly is a honeycomb construction having a plurality of through-holes and normally in a compressed state. Upon water permeation into the water-absorbent structure, the super-absorbent polymer is swollen and softened and the assembly is swollen so that the through-holes restore the initial state before the assembly has been compressed.

Abstract: In order to manufacture a sandwich panel using the RTM technique, a stack comprising a core (10) with open cells, a film (12) of intumescent material covering each of the faces of the core (10), a dry barrier fabric (14) covering each of the films (12) and an overlay of dry fibers (16) covering each of the barrier fabrics is placed in a mold. During polymerization of the films (12), pressurization of the mold and the presence of the barrier fabrics (14) prevent penetration of the foam into the overlays (16). The resin is then injected into the mold and then polymerized, without danger of penetration into the cells of the core (10).

Abstract: A honeycomb core material which is excellent in flame retardation, thermal insulation and noise insulation and has improved transportability and handling efficiency and which can be suitably used also for a sandwich structure of a curved shape as a foam has flexibility and elasticity, and a method for its production. A composite foam comprising a phosphoric acid type inorganic foam and a urethane type organic foam, obtained by foaming and curing an aqueous mixture containing a phosphorus-containing acid material, a curing agent, a blowing agent and a urethane polymer having NCO groups, is filled in cells of a honeycomb body having a cell size of from 3 to 100 mm and a porosity of from 92 to 99.5% according to JIS-A6931.

Abstract: A composite panel (10) and a method for forming the panel are described. The panel (10) comprises an inverted tray (14) of composite material such as fibre reinforced plastic. A transparent or translucent surface layer (12) is provided on the top surface (16) of the tray (14). A block of honeycomb (20) with a backing sheet (22) is bonded within the cavity defined by the top surface (16) and the side walls (18) of the tray (14). The panel may be illuminated by using an electro-luminescent film as the backing sheet (22) or by placing LEDs (30) in the cells (34) of the honeycomb material (20). The composite panel (10) may be used as flooring, to create partition walls, or simply as decorative panels.

Abstract: Stiffness-treated honeycomb sandwich structures which exhibit reduced core crush and/or reduced void content are provided. Additionally, stiffness-treated prepreg plies which exhibit increased frictional resistance when disposed on other prepreg plies are also provided. Further, associated starting materials and methods are provided.

Abstract: A trauma mitigation device is provided which includes, an enclosure having a fluid impervious barrier, a crushable matrix disposed within said enclosure, and a viscous fluid disposed within said enclosure. Both the matrix and the fluid absorb energy when subjected to an impact force. A composition to be used in the device is also provided. The composition includes a viscous fluid in an amount of about 60-80% by weight of the composition and a plurality of macrosphere particles, in an amount of about 20-40% by weight of the total composition, disposed within said viscous fluid.

Abstract: The present invention provides for a method to reduce the strength of the honeycomb of a jet turbine stator, increasing its machinability, with a resultant reduction in measured peak tooth temperature, while maintaining or even improving its high temperature capability, so as not to limit its operating environment. The air seal functionality is unaffected, and even improved in some instances. The machinability of the honeycomb is increased by using a light element diffused into the honeycomb ribbon to produce the effect of reducing its strength and ductility while maintaining the environmental resistance needed. The present invention also includes the stator honeycomb produced by the foregoing method.

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: The present invention relates to an epoxy resin composition for a fibre reinforced composite material, which is thermosetting resin composition where the glass transition temperature Tg of the cured material obtained by heating for 2 hours at 180° C. is at least 150° C., and the modulus of rigidity G′R in the rubbery plateau in the temperature region above the aforesaid Tg is no more than 10 MPa. In accordance with the present invention, it is possible to provide a fibre-reinforced composite material which is outstanding in its resistance to hot-wet environmental condition, impact resistance, and strength characteristics such as tensile strength and compression strength, and furthermore it is possible to provide a thermosetting resin composition and a prepreg outstanding in terms of their peel strength to a honeycomb core.

Abstract: The invention relates to an ultralight, sound and shock absorbing component set comprising at least one base layer (2), an intermediate layer (3) and a covering layer (6). The intermediate layer (3) consists of a plurality of hollow bodies (4) arranged next to each other, whose walls are perforated and which thus form a complex labyrinth of hollow spaces. The covering layer (6) preferably has a microporous stiffening layer (8) which generates an airflow resistance of 900 Ns/m3<Rt<2000 Ns/m3. The dimensions of the walls of the hollow bodies (4) are such that they allow for compression of at least 50% at a maximum plateau tension of 0.5 Mpa<&sgr;<1.2 Mpa and inelastically and fully convert an impact energy of approximately 0.5 MJ/m3 into deformation work.

Abstract: The present invention is a method for joining thermoplastic composite sandwich panels with thermoplastic welds (fusion bonds) made without autoclave processing of the joint. The preferred joint is a double interleaf staggered joint with supporting titanium doublers providing a tensile strength of at least 12,000 lb/in. The joint is particularly suited for joining sections of a cryogenic tank for spacecraft.

Abstract: A modular fiber reinforced polymer (FRP) composite deck module having one or more hexagonal components and one or more double trapezoidal components. A hexagonal component is a hexagonal cell with all sides being of equal length and forming a hexagonal space. A double trapezoidal component has a top side, a bottom side, a first trapezoid having a first top and a first bottom, and a second trapezoid having a second top and a second bottom. The first and second trapezoidal components are of equal dimensions and configured such that the first trapezoid is inverted resulting in the first top of the first trapezoid is adjacent to the second top of the second trapezoid, thereby creating a center seam and an extensive bonding surface. The double trapezoidal and hexagonal components are made of multiple layers of multi-axial fiber reinforcement and a resin matrix, the layers being continuous throughout the entire shape of the components.

Abstract: A sheet of aluminum is formed to a mold by applying gas pressure. Thermoplastic resin is heated and applied to the aluminum in a selected pattern through a nozzle. In one embodiment, the thermoplastic resin is applied to the aluminum sheet in a hexagonal pattern that transitions to a columnar pattern. In a further embodiment microballons or micro-spheres are added to the heated thermoplastic resin to reduce viscosity. A backing layer of aluminum sheet is formed to the patterned resin composite. Gas forming of the aluminum sheet results in aspect ratios of up to 0.6, and the sheet maintains a clean surface that directly bonds to the applied resin.

Abstract: Structurally strong composite sandwich panels are made using phenolic resin adhesives to bond the face sheets to the honeycomb. Certain configurations and combinations of phenolic resins and fire protection agents were found to provide low flame, smoke and toxicity (FST) panels which have high structural strength.

Abstract: A composite structure particularly useful as a firewall utilizing a sheet of carbon-carbon material formed with first and second, opposite, sides. The first side of the sheet is subject to flame impingement. The sheet is formed in sufficient thickness to provide structural integrity and prevent the penetration of the flame from the first side to the second side for a 15-minute period where the flame temperature is 2,000° F.

Abstract: A method for molding panels in a sheet molding system comprised of a thermoplastic sheet delivery station and two mold halves, the method comprising the steps of delivering two sheeting layers of thermoplastic material between the two mold halves; inserting a rigidizing insert between the two sheeting layers of thermoplastic material; closing the mold halves to bring the two sheeting layers of thermoplastic material in contact with the insert; and compressing the thermoplastic sandwich between the mold halves to form a panel. A thermoplastic-insert sandwich and a laminate panel comprised of thermoplastic layers abutting a pre-manufactured insert are also claimed.

Abstract: A structure for reducing shock transmitted from a source (6) to an equipment unit (7) in a hardware system, which structure includes a honeycomb cellular support member (2, 3, 4 or 5) carrying the equipment unit to be protected from shock and/or the source. At least some of the honeycomb cells are filled with rigid microgranules whose dimensional characteristics are preferably heterogeneous, within given limits.

Abstract: This invention relates to methods of making visually uniform, light transmitting panels and to the resulting panels, which include a cellular core sandwiched between two light transmitting sheets and possess improved light transmitting characteristics.

Abstract: The present invention is directed to cost-effectively provide a high-strength large vacuum heat-insulating panel with a honeycomb core of non-permeable independent cells by means of simplified instruments and method. One goal of the invention is that the core retains an original shape at its lateral ends from the beginning of a procedure of evacuating air into a vacuum condition till the end of panel bonding, and another is ensuring a long lasting air-tight sealing in the honeycomb core. The vacuum heat-insulating panel 100 according to the invention includes a vacuum core element (50) of non-permeable honeycomb structure and a surface element (60) bonded thereto by fusing an air-permeable bonding element (woven cloth made of fibrous adhesive of thermoplastic resin or unwoven cloth of the fibrous adhesive) 70. The surface element 60 has its edges bent to provide protection covers 65.

Abstract: The present invention describes an extrusion process for manufacturing a titanium-containing silicate glass honeycomb structure, having a variety of shapes and sizes depending on its ultimate application. The titanium-containing glass honeycomb has a very low coefficient of thermal expansion (CTE) and the CTE can be varied by adjusting the titanium level to match the CTE of members that are bonded to the honeycomb. Furthermore, the inventive honeycomb structure is lightweight, yet able to support heavy loads on its end faces. Therefore, the inventive honeycomb can be advantageously used as a light-weight support for such objects as mirrors. Especially contemplated is using these inventive honeycomb supports for mirrors used in extraterresial environments where temperature extremes are present. These honeycombs can be used singularly or in aggregates to provide such support.

Abstract: A modular fiber reinforced polymer (FRP) composite deck module having one or more hexagonal components and one or more double trapezoidal components. A hexagonal component is a hexagonal cell with all sides being of equal length and forming a hexagonal space. A double trapezoidal component has a top side, a bottom side, a first trapezoid having a first top and a first bottom, and a second trapezoid having a second top and a second bottom. The first and second trapezoidal components are of equal dimensions and configured such that the first trapezoid is inverted resulting in the first top of the first trapezoid is adjacent to the second top of the second trapezoid, thereby creating a center seam and an extensive bonding surface. The double trapezoidal and hexagonal components are made of multiple layers of multi-axial fiber reinforcement and a resin matrix, the layers being continuous throughout the entire shape of the components.

Abstract: The present invention pertains to a porous, macroscopically-expanded, three-dimensional, elastomeric web suitable for use in disposable absorbent articles such as bandages, diapers and pull-up diaper training pants, as well as a method for making the web. In a preferred embodiment the web has a continuous first surface and a discontinuous second surface remote front first surface. In a preferred embodiment the elastomeric web exhibits a multiplicity of primary apertures in the first surface of the web, the primary apertures being defined in the plane of the first surface by a continuous network of interconnecting members. Each interconnecting member exhibits an upwardly concave-shaped cross-section along its length. The interconnecting members terminate substantially concurrently with one another to form a secondary aperture in the plane of the second surface of the web.

Abstract: An energy absorbing device is formed of natural or synthetic resin material or composite material, wherein energy absorption is provided by a plurality of cup-shaped cells having a thin-walled construction with a circular cross section. The absorber is useful for automotive bumper impact and also for other applications, including automotive padding and general cushion applications.

Abstract: Thrust reverser inner wall structure comprising a thermally conductive nonmetallic carbon pitch fiber honeycomb core sandwiched between a top and bottom layer. The core is adhered by a reticulated layer of adhesive to a perforated carbon fiber top layer, and adhered to a base layer of nonmetallic, nonperforated carbon fiber reinforced fabric.

Abstract: Lightning protection utilizing lightweight electrically conductive coatings with a conductance of approximately 220 to 350 mhos per square co-cured or secondarily bonded to the outer surface of thin skin composite structure. Selection of either 2 to 3 ounces per square yard or aluminum mesh of 1 to 1.5 ounces per square yard, depending on corrosion compatibility, satisfy the conductance requirement and has shown superior lightning protection over heavier weight conductive coatings.

Abstract: A composite material includes five distinct layers of material: two thin outer layers or panels, a central rigid core and intermediate foam layers on both sides of the core which fill the regions between the core and outer panels. The core can be a wide variety of material but is preferably a rigid foam or wood having resin or epoxy impregnated fiber or fiber filled outer skins. An array of apertures extends through the core. During the fabrication process, the apertures facilitate cross flow of the foam and ensure even distribution thereof. As a finished product, the foam filled apertures ensure positive location and retention of the core within the foam. The foam may be any suitable injectable foam but is preferably a composition which remains resilient upon curing as such foam more readily accommodates dimensional changes between the layers due to, for example, ambient temperatures changes.

Abstract: This invention comprises a composite part (1) consisting of a top (11) and bottom (12) metal cover layer and a sandwich component (10) that comprises a core (13) made of a honeycomb structure, and at least one metal profile (20) equipped with a connecting surface (21) for the discharge of forces into the sandwich component (10), whereby the profile or profiles are joined to the sandwich component in a flat manner, and a method for its manufacture.

Abstract: A noise attenuation panel for an aircraft engine nacelle structure comprises a cellular core having a multiplicity of cells and a facing sheet having a multiplicity of holes which provide for gaseous fluid communication between the cellular core and the front face of the facing sheet. Each hole in the facing sheet has a bore diameter which increases along the bore in the direction of the rear face of the facing sheet throughout the bore or a part of the bore and which does not at any point of the bore decrease along the bore in the direction of the rear face of the facing sheet. Prior to assembly of the facing sheet and the core the holes are formed by electron beam drilling from an entrance face of the facing sheet through to an exit face and the facing sheet and the cellular core are assembled to form the panel in such disposition that the exit face forms the front face of the facing sheet and the entrance face forms the rear face of the facing sheet.