U.S. patent number 3,642,566 [Application Number 05/039,598] was granted by the patent office on 1972-02-15 for quasi-isotropic sandwich core.
Invention is credited to Irving E. Figge.
United States Patent |
3,642,566 |
Figge |
February 15, 1972 |
QUASI-ISOTROPIC SANDWICH CORE
Abstract
A structural core consisting of upper and lower sheets of a
fiberglas or like material. Each sheet defines parallel rows of
raised, tetrahedronal-shaped, hollow knobs. The upper sheet is
inverted over the lower one so that the edges of the tetrahedrons
abut whereby all tetrahedrons on the bottom sheet point up and all
tetrahedrons on the upper sheet point down in alternating sequence
along the rows. Each sheet is formed by placing it over a male mold
having upstanding tetrahedron shaped raised knobs, folding the
sheet between the tetrahedrons to produce puckers, applying bands
in the fold lines to hold the sheet on the male mold, coating the
sheet with an epoxy resin, cutting the bands and removing them,
inverting a female mold over the male mold and applying pressure
thereto, allowing the resin to cure, then removing the sheet from
the molds. The core is then formed by coating all edges of the
tetrahedrons on both sheets with a resin-type bonding material,
inverting the upper sheet and nesting it in the lower sheet so that
the edges of the upper tetrahedrons abut the edges of the lower
tetrahedrons and then bonded together, the core is then allowed to
cure.
Inventors: |
Figge; Irving E. (Newport News,
VA) |
Family
ID: |
21906335 |
Appl.
No.: |
05/039,598 |
Filed: |
May 20, 1970 |
Current U.S.
Class: |
428/180;
52/DIG.10; 156/196; 156/293; 428/116; 428/178 |
Current CPC
Class: |
E04C
2/326 (20130101); B32B 3/12 (20130101); Y10T
428/24661 (20150115); Y10S 52/10 (20130101); Y10T
428/24149 (20150115); Y10T 156/1002 (20150115); Y10T
428/24678 (20150115) |
Current International
Class: |
B32B
3/12 (20060101); E04C 2/32 (20060101); B32b
003/28 () |
Field of
Search: |
;161/68,122,127,130,131
;156/197,196,293 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Powell; William A.
Claims
What is claimed is:
1. A structural core comprising a pair of substantially identical
sheet walls, each sheet being provided with a series of
symmetrically disposed indrawn knobs of tetrahedronal shape the
bases of which are separated by triangular portions of the sheet
wall, one sheet being inverted and nested in the other sheet so
that the edges of said tetrahedronal knobs of said inverted sheet
abut the edges of the tetrahedronal knobs of the other sheet, and
the triangular sheet wall portions lying between adjacent knobs
form top and bottom surfaces of the core.
2. The core defined in claim 1 wherein said tetrahedronal shaped
knobs in both said sheets are hollow.
3. The core defined in claim 1 wherein said tetrahedronal-shaped
knobs are arranged on each sheet in longitudinal rows, each row of
knobs being in offset sequential relation to the knobs of an
adjacent row whereby two sides of all tetrahedrons are disposed in
oppositely inclining, parallel planes and the remaining sides are
disposed in parallel longitudinal planes, all planes intersecting
at the apices of the bases of said tetrahedrons.
4. The core defined by claim 1 wherein the edges of the inverted
tetrahedronal-shaped knobs are bonded to the edges of the
upstanding tetrahedronal knobs.
5. The core defined by claim 1 wherein all of the said
tetrahedronal-shaped knobs on both sheets are of the same height
whereby said sheet walls are disposed in spaced, parallel
planes.
6. The core defined by claim 1 wherein said tetrahedronal knobs of
one sheet point upwards while the tetrahedronal knobs of the other
sheet point downwards.
7. The core of claim 1 in which the tetrahedronal-shaped knobs of
each sheet are arranged in staggered rows with the bases of the
knobs in tip-to-tip relation to the bases of adjacent knobs whereby
the sides of the knobs are disposed in continuous intersecting
planes.
8. The core of claim 1 in which the tetrahedronal-shaped knobs of
each sheet are arranged in staggered rows with the triangular
portions of the sheet wall separating the knobs being disposed in
tip-to-tip relation with each other to form closed exterior plane
surfaces for the core.
Description
The invention described herein may be manufactured, used, and
licensed by or for the Government for governmental purposes without
the payment to me of any royalty thereon.
This invention relates to a constructional core of a honeycomb type
and more particularly to a core having quasi-isotropic
load-carrying properties.
Constructional cores of the honeycomb type have many uses. One such
use is in aircraft construction wherein the core must possess
quasi-isotropic load-carrying capabilities including tension,
compression, bending, and torsional rigidity. Conventional cores
usually consist of two sheets of material with the spacing means
sandwiched between the sheets. These cores often lacked structural
strength and it was hard to bond the elements together. Most
commonly used cores of the honeycomb type were capable of carrying
loads in only one direction, namely in a perpendicular direction to
the face sheets.
The present invention is an improvement over the conventional type
cores or panels and is made of but two pieces and lends itself to
mass production due to the simplicity of its manufacture. The
construction of the invention provides a panel that is capable of
load carrying in all directions due to the novel arrangement of the
tetrahedronal knobs which are bonded together at their edges.
It is therefore a principal object of this invention to provide a
constructional panel that possesses quasi-isotropic properties
including tension, compression, bending and torsional rigidity.
It is another object of this invention to provide a structural
panel that is lightweight and formed of but two sheets of a
moldable material.
A further object is to provide a constructional core of two
moldable sheets having indrawn knobs of tetrahedronal shape, the
tetrahedrons being bonded together along their edges.
A still further object is to provide a novel and improved method
for the manufacture of a structural panel of two moldable sheets
wherein each is intended to provide a series of tetrahedronal
shaped knobs, one sheet being inverted and nested in the other
sheet whereby the edges of the tetrahedrons abut and the edges
being bonded together.
A final object is to provide a method of making a structural core
which is lightweight, economical to manufacture and which possesses
isotropic load-carrying properties.
Other objects and advantages will be apparent from the following
description and drawings in which:
FIG. 1 is a fragmentary perspective view of one of the sheets
comprising the core;
FIG. 2 is a sectional detail view through one of the tetrahedrons
and taken along line 2--2 of FIG. 1;
FIG. 3 is a fragmentary top view of a completed core, the upper
sheet being broken away to expose the lower sheet;
FIG. 4 is a diagrammatic view showing a top tetrahedron nested
between three bottom tetrahedrons;
FIG. 5 is a fragmentary perspective view of an edge of the
completed core to illustrate positions of the upper and lower
tetrahedrons;
FIG. 6 is a fragmentary side view of the mold used in manufacturing
the core;
FIG. 7 is a similar view of the mold and showing a sheet secured to
the male mold by rubber bands;
FIG. 8 is a plan view showing in dotted lines the manner of folding
a sheet to produce puckers therein;
FIG. 9 is a similar view showing rubber bands in place to secure
the sheet on the male mold, and,
FIG. 10 is a fragmentary side view showing the mold closed and the
rubber bands removed.
Referring in detail to the drawing wherein reference character 1
designates generally one of the sheets used in fabricating the core
which is indicated generally by 2. Core 2 is composed of two
identical sheets, the upper sheet being indicated by 3 while the
lower sheet is indicated by 4. Sheets 3 and 4 are provided with
series of upstanding, tetrahedronal shaped, hollow knobs 5 and 5a
respectively. Knobs 5 and 5a are equal in dimensions and are
arranged on sheets 3 and 4 in parallel rows, the knobs in one row
being disposed on the sheet in offset relation with respect to the
knobs of the adjacent rows whereby two sides of all of the
tetrahedrons are disposed in oppositely inclining parallel planes
while third sides are disposed in longitudinal parallel planes, all
planes intersecting at the apices of their bases. This may readily
be observed by FIG. 4 in which three tetrahedrons 5 of lower sheet
4 and one tetrahedron 5a are shown diagrammatically. It will be
observed that sides of a tetrahedrons 5 lie in an inclining plane
P.sub.1, sides b lying in oppositely inclining plane P.sub.2 and
sides c in longitudinal plane P.sub.3 as shown. Plane P.sub.1,
P.sub.2, P.sub.3 intersect at d as shown.
Upper sheet 3 is inverted and nested in lower sheet 4 and bonded
thereto, so that the tetrahedrons 5a in the upper sheet 3 point
downward, while the tetrahedrons 5 of the lower sheet 5 point
upward whereby the edges of an upper tetrahedron will abut one of
the edges of three lower tetrahedrons 5 as shown.
Sheets 3 and 4 may be of a suitable material as needed, such as
fiberglas, plastic, or even metal. The core 2 may be of any size as
needed and a portion of a completed core is shown in FIGS. 3 and
5.
In FIGS. 6-10 is shown the method of forming one of the sheets 1. A
molding apparatus of a suitable material is used and consists of a
male mold 6 having upstanding tetrahedronal-shaped knobs 7. The
knobs are arranged on the mold 6 similar to a finished sheet 1 as
seen in FIG. 9. A female mold 8 having tetrahedronal-shaped
recesses 9 therein comprises the other member of the mold
apparatus. A sheet 1 is now placed over the male mold 6. Where the
sheet material is composed of frangible material such as woven
fiberglas or thin layers of plastic or metal, it is necessary to
preposition the material along the contours of one of the mold
sections in order to prevent material rupture during the molding
operation. In order to accomplish this prepositioning, the sheet
folded along a series of longitudinal and diagonal lines such as
lines 10 and 11 between the rows of tetrahedrons 7 on mold 6. This
prepositioning produces puckers 12 as shown in FIG. 7. Holding
bands 13 may be used to assist sheets that will not remain
positioned on the mold by placing them on the fold lines 10 and 11
as seen in FIG. 9. The bands may be of any available material as
they are removed and do not form part of the end product. Elastic
bands have been found to be especially useful as they snap out when
cut. Sheet 1 after being positioned is coated with a stiffening
material such as an epoxy resin. The bands 13 are cut and removed
and pressure is applied to the mold. The resin is allowed to cure
and the sheet removed. Two sheets, 3 and 4 are fabricated in this
manner. The edges of all tetrahedrons 5 and 5a are coated with an
adhesive such as an epoxy resin and one sheet is inverted and
nested in the other sheet so that the edges of the tetrahedrons
abut, as best seen in FIG. 4. The core is now allowed to cure and
removed from the mold. If the sheets are of a metal, welding the
edges or other well-known metal-working procedures may be employed
to join the sheets.
It is apparent from the foregoing that a unique, lightweight, high
strength, easily fabricated sandwich constructional core has been
provided and one which has quasi-isotropic load-carrying
capabilities including tension, compression, bending and torsional
rigidity.
* * * * *