Method of making an offset corrugated sandwich construction

• US 5,348,601 A
• Filed: 06/23/1993
• Issued: 09/20/1994
• Est. Priority Date: 06/23/1993
• Status: Expired due to Fees

• Current Assignee: the united states of america as represented by the secretary of the navy
• Original Assignee: the united states of america as represented by the secretary of the navy
• Inventors: Ray, Hemen
• Primary Examiner(s): Ball, Michael W.
• Assistant Examiner(s): Maki, Steven D.
• Application Number:
  US08/082,068
• Time in Patent Office: 454 Days
• Field of Search: 156/155, 156/204, 156/210, 156/292, 428/116, 428/118, 428/179, 428/181, 428/185, 428/186, 52/795, 52/799, 52/800, 52/807, 264/DIG. 44, 264/257, 264/258, 264/313, 249/61
• US Class Current: 156/155
• CPC Class Codes: B29C 53/22 Corrugating
• CPC Class Codes: B29D 24/004 the structure having vertical or oblique ribs
• CPC Class Codes: Y10S 264/44 using destructible molds or cores in molding processes
• CPC Class Codes: Y10T 156/1025 to form undulated to corrugated sheet and securing to base with parts of shaped areas out of contact

Abstract

A method for making an offset corrugated core sandwich construction is diosed. Mandrels of preestablished form and size are arranged into a pattern in a confined area. After covering the mandrels with a release film, strips of pliable, uncured composite material are arranged in a "peak-to-valley" pattern with adjacent strips being out of phase by 180 degrees. Selected mandrels are replaced by a granular mixture and top and bottom face sheets are fitted to the arrangement. After curing, all mandrels are removed from the construction.

Claims

1. A method for making an off-set corrugated core sandwich construction comprising the steps of:

placing shaping mandrels into a prearranged pattern wherein each mandrel has an exterior surface;

wrapping a release film over the exterior surface of each of said mandrels;

arranging a first strip of pliable composite material to bend over and around said mandrels to from alternating crests and troughs;

arranging subsequent strips of pliable composite material to form alternating crests and troughs wherein each strip is approximately 180°

out of phase with an adjacent strip;

attaching a face sheet to the crests of the strips and attaching a face sheet to the troughs of the strips to form an off-set corrugated core sandwich construction;

replacing selected of said mandrels with a granular mixture;

curing the construction; and

removing the granular mixture and release films.

2. The method according to claim 1 wherein said shaping mandrels are hexagonal and triangular solid forms.