Multiple-layer structures and joining method for honeycomb, foam and lightweight materials

摘要

Multiple layers of honeycomb or foam core lightweight materials are bonded together side-by-side to increase strength, to customize strength relationships in relation to form for particular structural components and to provide a base for strong connections to honeycomb and foam structures. Increased strength results from utilizing outside layers as skins for some embodiments with an effect of progressive increase of strength of the core with the multiple layers. Connection strength is provided by formation of connection bays in one or more outside layers to which connection members of structural components are bonded in the connection bays. The outside or distal core layers can be higher density and higher strength than inside core layers for dynamic and impact- related use-conditions in addition to providing a thicker and stronger surface to which other structures and other members can be connected. An aircraft wing constructed using this method illustrates high-density, high-heat and high-impact strength of a contoured distal core in relationship to a low-density contoured proximal core.