Stock material or miscellaneous articles – Structurally defined web or sheet – Honeycomb-like
Reexamination Certificate
2000-07-21
2003-10-07
Jones, Deborah (Department: 1775)
Stock material or miscellaneous articles
Structurally defined web or sheet
Honeycomb-like
C428S304400, C428S313300, C428S313500, C428S314200, C428S314400, C428S315500, C428S316600, C428S317900, C428S364000, C428S367000, C428S369000, C428S402000, C264S045300, C264S051000, C264S054000, C264S320000, C264S321000, C264S176100
Reexamination Certificate
active
06630221
ABSTRACT:
BRIEF DESCRIPTION OF THE INVENTION
Monoliths of essentially uniform density containing in situ-expandable thermoplastic particles essentially uniformly dispersed in a thermosettable or thermoplastic matrix resin system that is incompatible with the particles, are described. Composites of the monolith and core-holding structures are made by incorporating the monolith into the core-holding structure, thermally treating the matrix resin of the monolith whereby expansion of the in situ-expandable thermoplastic particles causes the thermally treated monoliths to faultlessly interface with the wall(s) of the core-holding structures. The invention relates to core supported composite structures, fasteners, adhesives, paneling, insulation, and other structures that employ the invention as a component.
BACKGROUND TO THE INVENTION
Sandwich construction forms a major part of aerospace manufacturing; it is employed to some degree in almost every type of flight vehicle. Lightweight structural panels and panel systems for a wide variety of applications are industrially offered. They utilizing various laminating techniques to adhere thin, stiff “skins”, such as aluminum, steel, hardboard and fiberglass onto lightweight core materials, like honeycombs, urethane foams and balsa. The resulting panel is lightweight and strong.
Honeycomb sandwiches, i.e., honeycombs, are preferred structures in the fabrication of lightweight structures typically used in the aerospace and other commercial markets. The core material is usually “sandwiched” between skins of aluminum or other high strength composite material. A bonding adhesive is used to attach the “skin” material to the honeycomb core. The resultant honeycomb panel offers one of the highest strength to weight constructions available. For instance, the floor panels of most airliners use the lightweight/high strength construction of honeycomb. Aircraft engine nacelles, flaps, overhead bins and galleys all are constructed from honeycomb core.
A honeycomb sandwich, or simply “honeycomb,” may be called a multicellular structure, and it may be made of paper, plastic, fabric or metal, and other materials. The core of the sandwich is the honeycomb, a structure composed of row upon row of framed cells, or holes or wells, resembling the honey-storage facility of a beehive and characterized by a hexagonal or rectangular shape. To each side of the core are bonded extremely thin sheets of metal, creating the sandwich, which is far lighter yet has greater resistance to bending than a comparable thickness of metal plate. Aluminum is the most extensively used metal, in both the core and the facing sheets, but the technique is applicable to a large number of metallic and nonmetallic materials.
For example, M. C. Gill Corporation offers the following honeycomb products to Boeing's specifications:
Specification
Number
Q
1.
M
2.
Product Code Number and Description
BMS 4-7C
x
Gillfab 4030 - Aluminum facings/
aluminum honeycomb core sandwich
panel.
BMS 4-10
x
Gillfab 5040Z and 5042 - Aluminum
Ty 1, Gr 1
facings/end grain balsa wood core
sandwich panel.
BMS 4-10
x
Gillfloor ® 5007A and 5007B - Fiberglass
Ty 2
cloth facings/end grain balsa wood core
sandwich panel for aircraft flooring.
BMS 4-17
x
Gillfloor 4417, Ty I thru Ty VI and
Drawing 69B15779 (Ty V) - Uni-
directional fiberglass reinforced epoxy
facings/Nomex honeycomb core sandwich
panel.
BMS 4-20
x
Gillfab 4409, Ty II and Ty III (Ty I is
obsolete) - Unidirectional graphite re-
inforced epoxy facings/Nomex honeycomb
core sandwich panel.
BMS 4-23
x
Gillfab 5424, Ty I and Ty II -
Unidirectional S-glass facings/aluminum
honeycomb core sandwich panel.
BMS 7-326
x
Gillfloor 5433C - Aluminum facings/uni-
direction fiberglass reinforced epoxy core
sandwich panel.
BMS 8-2
x
Gillfab 1076A - Fire resistant polyester
Cl 1 Gr A
glass cloth cargo liner.
BMS 8-2
x
Gilliner ® 1366 - Extremely high
Cl 2 Gr A
impact, puncture, and fire resistant poly-
ester glass cloth cargo liner.
BMS 8-2
x
Gilliner 1366T - Same as 1366 but with a
Cl 2 Gr B
1 mil white Tedlar ® overlay.
BMS 8-2
x
Gillfab 1076B - Fire resistant polyester
Cl 3
glass cloth cargo liner.
BMS 8-100 Gr A
x
Gillfab 1108 - Epoxy/unidirectional fiber-
and B, Cl 1
glass cargo liner.
BMS 8-13 Ty 1
x
Gillfab 1137 - Nylon resin
ylon
cloth fuel cell liner.
BMS 8-223
x
Gillfab 1367 - Phenolic/S-2 glass cloth
Cl 2
cargo liner with low smoke emission.
BMS 8-223
x
Gillfab 1367A - Phenolic/fiberglass cargo
Cl 2
liner with low smoke emission.
BMS 8-223
x
Gillfab 7146 - Phenolic/S-2 glass cargo
Cl 2
liner replacement kits.
BMS 8-223
x
Gillfab 1367B - Phenolic/fiberglass cargo
Cl 4
liner with low smoke emission.
BMS 8-124
x
Gillcore ® HD - Nomex honeycomb.
BMS 8-262
x
Gilliner 1566 - Kevlar ®/polyester cargo
Cl 1, Gr B
liner - very light weight.
1.
Q = Qualified to specification
2.
M = Meets the requirements of specification
To illustrate some of the physical characteristics of commercial honeycombs, the following is taken from Plascore Inc. (615 North Fairview Ave. Zeeland, Mich. 49464) PAMG-XR1 5052 Aluminum Honeycomb literature:
Typical Property Values
PAMG-XR1 5052 Aluminum Honeycomb
Plate Shear
Plate Shear
Honeycomb
Bare Com-
Strength
Strength
Modulus
Modulus
Designation
pression
(PSI)
(PSI)
(KSI)
(KSI)
Cell
Foil
Density
Strength
Modulus
“L”Direc-
“W”Direc-
“L”Direc-
“W”Direc-
Size
Gauge
(PCF)
(PSI)
(KSI)
tion
tion
tion
tion
1/8
.0007
3.1
270
75
210
130
45
22
1/8
.001
4.5
520
150
340
220
70
31
1/8
.0015
6.1
870
240
505
320
98
41
1/8
.002
8.1
1400
350
725
455
135
54
5/32
.0007
2.6
5/32
.001
3.8
5/32
.0015
5.3
5/32
.002
6.9
5/32
.0025
8.4
3/16
.0007
2.0
3/16
.001
3.1
270
75
210
130
45
22
3/16
.0015
4.4
500
145
330
215
68
30
3/16
.002
5.7
770
220
460
300
90
38
3/16
.0025
6.9
1080
285
590
375
114
46
3/16
.003
8.1
1400
350
725
455
135
54
1/4
.0007
1.6
85
20
85
50
21
11
1/4
.001
2.3
165
45
140
85
32
16
1/4
.0015
3.4
320
90
235
150
50
24
1/4
.002
4.3
480
140
320
210
66
29
1/4
.0025
5.2
670
190
410
265
82
35
1/4
.003
6.0
850
235
495
315
96
40
1/4
.004
7.9
1360
340
700
440
130
52
3/8
.0007
1.0
30
10
45
30
12
7
3/8
.001
1.6
3/8
.0015
2.3
165
45
140
85
32
16
3/8
.002
3.0
260
70
200
125
43
21
3/8
.003
4.2
460
135
310
200
65
29
Other Plascore honeycomb products include:
PAMG-XR1 5056 aluminum honeycomb is a lightweight core material which offers superior strength and corrosion resistance over PAMG-XR1 5052 and PCGA Commercial grade aluminum core. PAMG-XR1 5056 core is made from 5056 aluminum alloy foil and meets all the requirements of MIL-C-7438.
PCGA-XR1 honeycomb is a lightweight core material offering excellent strength and corrosion resistance for industrial applications at low cost. PCGA-XR1 core is made from 3003 aluminum alloy foil.
PN Aramid Honeycomb is a lightweight, high strength, non-metallic honeycomb manufactured with aramid fiber paper (DUPONT Nomex(™) or equivalent). The aramid paper is treated with a heat resistant phenolic resin. This core material exhibits excellent resiliency, small cell size, low density and outstanding flame properties.
Plascore polycarbonate honeycomb core exhibits a unique cell structure: The core has 3 orientations vs. the 2 orientations common with other cores, making its properties more uniform. Each cell has a tubular form and inherently stable.
Plascore polypropylene honeycomb core exhibits a unique cell structure: The core has 3 orientations vs. the 2 orientations common with other cores, making its properties more uniform. Each cell has a tubular form and inherently stable.
Plascore polypropylene honeycomb is supplied with or without a non-woven polyester veil for better bonding. It is also supplied with or without a film barrier under the polyester veil to limit the amount of resin consumption.
Euro-Composites® sell honeycombs with cell sizes ranging from 3.2 to 19.2 mm and a density of between 24 and 200 kg/m
3
, in hexagonal and rectangular-celled cores.
Aerospace manufacturers started the use of honeycomb products in airplanes and spacecraft because, pound-for-pound, it's the str
Boss Wendy
Dexter Corporation
Dorsey & Whitney LLP
Jones Deborah
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