Abstract: A composite panel having a non-adhesion portion is mounted on a stationary table and a bending table and is fixed thereto by vacuum adsorption pads. An upper portion bending table is mounted on a face sheet providing the non-adhesion portion. The face sheet is secured using the vacuum adsorption pad on the bending table. The bending table is rotated, so that the face sheet is bent. The center core member is cut with a V-shape. An adhesion agent is coated. Next, by rotating the lower bending table, the other face sheet and the center core member are bent so that the core member is adhered to the upper face sheet. Without causing a gap between a face sheet and a center core member and a partial contact, an integral bending processing of a flat sheet shape composite panel can be realized. In addition to this, to assurance adequate strength in a bending processing portion of the composite panel, it is unnecessary to provide a separate member and the like.

Abstract: A structural reinforcement for a hollow member comprising a rigid reinforcing member having a shape that substantially conforms to the cross section of the section of the hollow member to be reinforced with an expandable adhesive material over at least a portion of the surface of the rigid reinforcing member sufficient to bond the reinforcing member to at least two nonparallel internal surfaces of the structure.

Abstract: A composite building component includes a non-planar molded composite web having two outer zones and two angled zones wherein the caliper of the angled zones differs from the caliper of at least one of the outer zones, and a flange disposed on an outer surface of an outer zone. A method of providing a composite building component also is disclosed.

Abstract: An extruded hollow thermoplastic board, which includes a pair of flat and parallel sheets spaced apart and interconnected by extending ribs, generally has a plurality of depression bands in the areas where the flat sheets and extending ribs are joined. The bands, which negatively affect the surface flatness, are especially apparent for crystalline thermoplastic materials. A hollow thermoplastic board, which effectively reduces the depth of the depression bands by inclusion of locationally fixed gas pockets in the rib area during production, is disclosed in the present invention. The hollow thermoplastic board of the present invention substantially enhances the surface smoothness and is highly beneficial to applications such as printing, lamination and graphic art. The present invention also provides a method for production of the hollow thermoplastic boards of smooth surfaces.

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: A composite structure has composite skin layers and at least two elongated stiffener/spacer composite members interposed between the skin layers. The stiffener/spacer composite members are arranged generally longitudinally of the skin layers in spaced-apart relation laterally. Each of the skin layers is formed by assembling a layer of an uncured resin-impregnated fiber material on a forming surface of a jig. Each stiffener/spacer composite member is formed of an uncured resin-impregnated fiber material that is laid up over an elongated hollow mandrel of a stiffened fabric and is assembled to one of the uncured skin layers. The jigs are juxtaposed to form a sandwich with the assembled uncured composite layers, which are then vacuum-bagged and co-cured under a predetermined pressure and a predetermined temperature to render the structure unitary.

Abstract: An elevator cab door having a honeycomb core comprises an elevator door frame adapted for attachment to the entryway of an elevator cab. The door frame has a front skin panel and a rear skin, and a core comprising a plurality of honeycomb cells sandwiched between the front and rear skins. The door assembly components, including the frame, core and the skins are formed from a light, strong material such as aluminum. The structure is lightweight, easily adaptable to varying opening and closing velocities, and less prone to imparting dangerous impact loads on passengers in case of hazardous situations.

Abstract: A core material for a composite light weight building panel formed from a settable mixture, said mixture including an acrylic, polymer-based resin comprising:

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: The invention relates to a self-supporting and load-transferring construction element (1) with at least one, preferably two cover layers (7), on which preferably several strip-shaped spacing elements (18) are placed, distributed on an inner facing surface (15a) of the cover layer (7), which are joined to the cover layer (7) in a non-positive and/or a positive join by means of a curable joining and/or fixing means (70). The cover layer (7) and/or the spacing elements (18) are made from randomly oriented wood or wood material elements (73) joined by a binder with cavities (75) and pores (74) disposed in between them.

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: A double walled reinforcement structure and method for making a double walled reinforcement structure having a plurality of longitudinally extending and nested structural members. Each structural member comprises a first cell having a first cross-section and a second cell having a second cross-section. The second cell is positioned within the first cell and the second cell contacts the first cell in a plurality of locations to provide mutual support of the cells in a manner increasing the tensile and compressive strength of the 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: Composite joint for fitting at least one external member to a sandwich panel and panel integrating at least one such joint. To permit the transmission of static and/or dynamic stresses between at least one external member and a sandwich panel, into said panel is integrated at least one composite joint (10). Said joint comprises a plurality of juxtaposed, elementary, tubular cells (12), oriented in the panel thickness direction, as well as at least one stress introduction cell (12a), in which is fitted a rigid part (14) for fixing the external member. The tubular cells (12) comprise composite walls formed from braided fiber roves and resin.

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: The invention relates to a light construction panel with an outer frame and a core, the frame and the core having the same material thickness, and also with an upper and a lower cover sheet which cover the frame and the core. The core consists of an inner part made from light construction material and an upper and lower sealing layer. Such a panel is distinguished by a particular rigidity. Moreover the transition between frame and core no longer shows on the surface of the panel.

Abstract: The invention provides a rivet and method of installing the rivet to attach honeycomb material to other materials. The rivet is installed by drilling a hole through the materials. A back side sleeve of the rivet is inserted through one end of the hole while a front side sleeve with a stem member inserted therethrough is inserted through the other end of the hole such that the head of the stem member and the sleeve portion of the front sleeve are positioned within the sleeve portion of the back sleeve. The shank portion of the stem member is then pulled such that the head of the stem member expands the sleeve portions of the front and back sleeves into the materials to attach the rivet to the materials. A locking collar is also provided to lock the stem member to the front sleeve upon continued pulling of the stem member.

Abstract: A method of making a composite structure from a support structure or a plurality of support structures laid side-by-side on a base, is disclosed. The support structure is formed from frameworks each comprising a tube of a flexible material divided by dividing walls of a flexible material into an array of compartments. The frameworks are then filled with a suitable filler material. The frameworks have compartments with three different sizes which have advantages in the construction of certain composite structures.

Abstract: A structural panel for building structures such as residential houses or the like comprises a honeycomb or other cellular core sandwiched between two metal face sheets and surrounded by a metal frame. Frame members of the frame form mechanical interlocking connections with the face sheets of the panel. Side frame members of the panel define interlocking protrusions and channels for making interlocking joints between panels. A building structure employing the panels for forming floor and roofs includes brackets that extend into a gap between the side frame members of the panel at the panel joints and attach to the side frame members. The brackets are used for attaching the panels to other parts of the structure.

Abstract: This invention is directed to a structural laminate for use as a dasher board comprising a first layer of fiberglass, a layer of rigid foam made of polyvinylchloride, a first bonding layer operatively arranged to bond with the first fiberglass layer and the foam layer, a second layer of fiberglass, and a second bonding layer operatively arranged to bond with the second fiberglass layer and the foam layer. The invention is also directed to a method of making the structural laminate, comprising the steps of bonding a first layer of fiberglass to a foam layer; bonding a second layer of fiberglass to the foam layer; and sealing the bonded layers of fiberglass and foam.

Abstract: A stiffener is provided for reinforcing a hollow structure having a pair of spaced walls with a pin extending across the walls. The stiffener includes a carrier member with a layer of expandable polymer which creates a structural foam when the polymer is later expanded. The stiffener could comprise a horseshoe shaped laminate shaped to fit over the pin of the hollow structure so that when the polymer is expanded it forms a structural foam intimately bonded to the pair of spaced walls.

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 invention relates to a method of making a reinforced composite panel of the sandwich type having a cellular core.

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 polymeric twin wall board which includes a first substantially planar sheet forming the upper side of the board, a second substantially planar sheet forming the underside of the board and a plurality of spaced longitudinally extending webs connecting the first substantially planar sheet to the second substantially planar sheet wherein the difference between the level of the top surface of the first substantially planar sheet adjacent to its juncture with any of the longitudinally extending webs and the level of the top surface of the first substantially planar sheet intermediate any of the adjacent longitudinally extending webs is no more than about 1% of the average distance between adjacent longitudinally extending webs.

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: A sandwich panel is manufactured-by providing: a first step (a), (b) of attaching another end portion of an insert 1 whose one end portion is made sharp to an inner side of a facing member 2 in which a hole is cut in advance; a second step (c) of pressing the insert 1 into the core member 4 such that the one end portion of the insert 1 force-cuts a core member 4; and a third step (d) of attaching another facing member 2 to a side of the core member 4 opposing the insert-inserting side thereof.

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: A colinear laminate honeycomb panel permits the use of two or more different materials to form a single panel. In this manner, a retractable cover for an architectural opening may be formed that has a different appearance depending upon which side of the panel is being viewed. The resultant panel is formed by attaching a plurality of elongated precursor tubular cells, wherein each precursor tubular cell itself comprises at least two strips of material held in proximity to one another by a common carrier strip.

Abstract: This invention generally pertains to a composite building material comprising a lightweight core with a thin fiber cement facing on one side of the core and a second facing material on the other side. The fiber cement facing that is used on at least one of the faces of the building material is {fraction (3/16)}″ or less, more preferably ⅛″ or less. The green fiber cement facing is preferably formed by a slurry-dewatering process to form a sheet that is in a plastic, uncured, state prior to manufacture of the composite. The composite building material is assembled in an uncured state and then cured.

Abstract: A prefabricated concrete panel for building floors in civil or industrial structures, comprising a concrete body with a reinforcement provided with portions which protrude from one of the larger faces of the body of the panel which constitutes extrados of a floor and are designed to be embedded in the casting of the topping of the floor. At least one first shaped sheet is provided inside the body of the panel, is made of thermally insulating material, is interposed between the two larger faces of the panel body and forms, between the two larger faces of the panel body, a ventilation chamber which is composed of a plurality of mutually connected cells.

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 hollow structural member is reinforced by a housing in the form of a framework exposed structural foam on the housing. The housing is placed in the structural member at an orientation with its longitudinal axis perpendicular to the longitudinal axis of the structural member so that the foam is disposed directly against opposed walls of the structural member. Upon curing the foam becomes intimately bonded to the opposed walls of the structural member and to the housing for reinforcing the structural member. Preferably the housing is formed by extrusion so that it can be cut to size across its extrusion axis.

Abstract: A press-molded door including a reinforcing structure having a plurality of hollow vertical stiffeners joined by a horizontal web, two of the stiffeners arranged on opposite edges of the reinforcing structure with a groove formed in an edge face thereof, a T-shaped stile arranged in each edge stiffener with a tongue that fits into the groove, and front and back panels arranged on opposite sides of the reinforcing structure.

Abstract: A panel system includes a first skin, a second skin, a web core constructed from sheet material for securing the skins together in a spaced, sandwich relationship, and a connecting means for affixing the web core within the skins. The web core includes a plurality of spaced apart longitudinal members having longitudinally spaced projections extending therefrom and further having transversely aligned, longitudinally spaced slots therein. The web core further includes a plurality of spaced-apart, transverse cross members each having spaced slots therein receiving the longitudinal members at corresponding transversely aligned slots thereof to provide an interlocked grid between the first and second skins. The grid is connected to the skins utilizing the projections, which extend through slits in the skins to facilitate welding or otherwise bonding the components.

Abstract: A structural panel for use in building structures or in the formation, finish or decoration thereof includes an outer sheet and a connector sheet with a plurality of collapsible or compressible dividers therebetween. The panel in a rest condition is expanded and of a desired thickness for final use but can be compressed into a relatively thin thickness or profile for shipping purposes. The panel is very lightweight but structurally strong and can be selectively bent in one transverse direction if desired. The panel can be easily cut or formed into any predetermined size or shape.

Abstract: An expandable and contractible honeycomb insulating panel is described. The panel is formed by attaching a plurality of adjacent embedded tubular cell units, wherein each embedded tubular cell unit comprises at least one side having multiple layers of material. In this manner, the panel has superior insulating or light blocking capabilities in a volume comparable to a honeycomb panel made of tubular cells having a single layer of material. In another form, a retractable cover for an architectural opening is described that includes such a honeycomb insulating panel. Also, the honeycomb insulating panel may be enclosed to provide insulation.

Abstract: A prefabricated structural building panel is disclosed. The panel includes a first sheet having inner and outer planar surfaces. A plurality of structural ribs are disposed on the inner surface of the first sheet and are interconnected to form a geometric design having a plurality of chambers. The first sheet and the structural ribs are integrally formed as a single unit from a fiber and fly ash composite material. In preferred form, the cement composite includes a mixture of a commercial grade fly ash having a high lime content and a dry flue-gas desulfurized fly ash.

Abstract: The present invention concerns a manufactured article impervious to water, the water being rain water, water coming from a water-bearing stratum, and/or from concrete. The manufactured article of the invention may be used in building of habitations, factories, tunnels, and/or submarine structures and the like, the article comprising a leakproofing material. The manufactured article further includes a coating constituted by a film made of a material, the water-solubility of which is kept under control, the film delaying the leakproofing material hydration process for a predetermined period of time from between 1 and 30 days.

Abstract: The present invention provides contoured crushable composite structural members and methods for making the same. The contoured structural members comprise composite materials sandwiching a support or stabilizing structure. The contoured structure can be provided by tube rolling (or roll wrapping) the composite materials and the support structure together and then, if necessary, bonding them or connecting them. The structural members are made crushable by incorporating an initiator into the structures of the members. With a contoured, crushable, and generally non-flat structure, applications for the structural members of the present invention are nearly limitless.

Abstract: An improved high-density glass wool rigid panel for use in the construction of air distribution ducting in air conditioning and heating installations of the sort made of a box-shaped high-density glass wool body with optional glass fiber reinforcing mesh is disclosed. The rigid panel is formed with a step on opposite sides, covered with aluminum strips on the larger surfaces, wherein there is an overlap of said aluminum strips on step running right around its smaller side.

Abstract: A modular fiber reinforced polymer (FRP) composite structural panel component for structural support systems having a plurality of cells adjacently connected forming a top side, a bottom side, a first edge side and a second edge side. Each cell is defined by at least four sides, wherein at least two adjacent sides intersect at an obtuse angle resulting in the first edge side and the second edge side providing a means for joining two panel components and having an extensive bonding surface. A structural panel component is comprised of a plurality of layers of multi-axial fiber reinforcement, e.g., multi-axial fabrics, mats, woven cloth and unidirectional rovings, and a resin matrix, and the layers are continuous throughout the shape of the cells and a structural panel component. The structural panel component is manufactured using the Vacuum Assisted Resin Transfer Molding or pultrusion process.

Abstract: A powder-formed cellular honeycomb body of novel tapered, curved and/or very high cell density configuration is provided through a reforming procedure wherein a precursor honeycomb shaped from a plasticized powder batch material is filled with a compatible plastic filler, reshaped at a temperature at which the plastic deformation characteristics of the honeycomb and filler are matched, and then solidified after removal of the filler to fix the final configuration of the body.

Abstract: A prefabricated concrete panel for building floors in civil or industrial structures, comprising a concrete body with a reinforcement provided with portions which protrude from one of the larger faces of the body of the panel which constitutes extrados of a floor and are designed to be embedded in the casting of the topping of the floor. At least one first shaped sheet is provided inside the body of the panel, is made of thermally insulating material, is interposed between the two larger faces of the panel body and forms, between the two larger faces of the panel body, a ventilation chamber which is composed of a plurality of mutually connected cells.

Abstract: A roof structure comprises at least one ducted plastics panel having a top wall, bottom wall, and connecting walls, therebetween, said at least one panel being cut to a desired size and having an open space between the top and bottom walls and the last connecting wall, and an adaptor located in said open space, the adaptor having formations thereon for coupling to a glazing bar.

Abstract: A reinforced panel structure made by impregnating resin in a knitted fabric and allowing the resin to cure. The fabric comprises first and second spaced layers (1,2) which are interlinked by an intermediate pile layer (3) comprising two sets of ribs (4,5). The ribs (4) comprise monofilament yarns having a relatively high stiffness sufficient to provide a restoring force during impregnation of the fabric with resin. The ribs (5) are made from multifilament yarns, spun yarns or composite yarns, selected for desired properties of the finished fabric and/or for their wetting properties during impregnation.

Abstract: A walk-in refrigerator/freezer having a plurality of walls and a ceiling is provided. The refrigerator/freezer also includes a door and a floor. The floor includes a top wear surface, and a metal support grid beneath the top wear surface. The metal support grid has a plurality of apertures. An insulation material is located beneath the metal support grid. The insulation material passes through the apertures of the metal support grid and bonds to the wear surface.

Abstract: A structural honeycomb panel building system including fabrication methods and equipment provides integrated, modular structural components such as floors, walls, ceilings, trusses and roof members that can replace materials conventionally used in frame buildings. The panels are substantially impervious to moisture and other environmental hazards and may be inexpensively fabricated and assembled at the building site. The structural panels are fabricated, oriented depending upon the load bearing characteristics of each individual panel, interfitted and assembled to provide an assembly of structural panels with predetermined load bearing properties.

Abstract: A covering plate (5), for flooring in conveyances such as a railway car, is provided with a securing track (11) for securing seats, etc. The covering plate (5) is formed by a sandwich structure having a central core (24) arranged between an outer plate (25), which extends across the entire size of the covering plate, and second outer plates (26). The securing track (11) is formed in a profile (27) embedded in the sandwich structure so that a securing track (11) extends at a right angle to lateral edges (14) of the covering plate (5). As either end of the profile is provided with tracks (29) for receiving tight-fitting pins (30), a floor structure can be mounted easily and rapidly.