Structure including a plurality of cells of cured resinous material, method of forming the structure and apparatus for forming the structure

Abstract

A structure that includes a plurality of cells of a cured resinous material. Each cell is joined to at least one other cell.

We claim:  
     
         1 . A structure, comprising: 
 a plurality of cells of a cured resinous material, each cell being joined to at least one other cell.    
     
     
         2 . The structure according to  claim 1 , wherein the cells are solid.  
     
     
         3 . The structure according to  claim 1 , wherein the cells are hollow.  
     
     
         4 . The structure according to  claim 1 , wherein the hollow cells are filled with fluid.  
     
     
         5 . The structure according to  claim 1 , wherein the fluid is a gas.  
     
     
         6 . The structure according to  claim 1 , wherein the fluid is a liquid.  
     
     
         7 . The structure according to  claim 1 , wherein the resinous material comprises an epoxy curable with ultraviolet radiation.  
     
     
         8 . The structure according to  claim 4 , wherein an interior of the cells has a fluid pressure substantially similar to an ambient pressure external to the cells.  
     
     
         9 . The structure according to  claim 1 , wherein the cells all have a similar size.  
     
     
         10 . The structure according to  claim 1 , wherein the cells are joined together to form a wall of a tubular structure having continuous walls.  
     
     
         11 . The structure according to  claim 1 , wherein the cells are arranged in a plurality of parallel planes.  
     
     
         12 . The structure according to  claim 11 , wherein cells in plurality of adjacent planes are arranged in different positions orthogonal to the planes.  
     
     
         13 . The structure according to  claim 11 , wherein the cells in a plurality of adjacent planes are aligned in a direction perpendicular to the planes.  
     
     
         14 . The structure according to  claim 11 , wherein the number of cells in each plane differs.  
     
     
         15 . A method of forming a structure, the method comprising: 
 forming a plurality of individual cells each comprising a mass of uncured resin;    contacting some of the cells with others; and    curing the resin.    
     
     
         16 . The method according to  claim 15 , further comprising: 
 injecting fluid into the masses of uncured resin to inflate the cells of resin.    
     
     
         17 . The method according to  claim 16 , wherein the fluid is a liquid.  
     
     
         18 . The method according to  claim 16 , wherein the fluid is a gas.  
     
     
         19 . The method according to  claim 17 , further comprising: 
 solidifying the liquid after injecting it into the cells.    
     
     
         20 . The method according to  claim 15 , wherein the structure is formed by sequentially forming the cells in a plurality of planes and joining cells in each plane to cells in an adjacent previously formed plane of cells.  
     
     
         21 . The method according to  claim 20 , wherein the number of cells formed in each plane differs.  
     
     
         22 . The method according to  claim 20 , wherein cells in a plurality of adjacent planes are arranged in different positions orthogonal to the planes.  
     
     
         23 . The method according to  claim 20 , wherein cells in a plurality of adjacent planes are aligned in a direction perpendicular to the planes.  
     
     
         24 . The method according to  claim 16 , further comprising: 
 evacuating the fluid from the interior of the cells after curing the resin.    
     
     
         25 . The method according to  claim 24 , further comprising: 
 injecting another fluid into the cells after evacuating the fluid utilized in inflating the cells.    
     
     
         26 . The method according to  claim 25 , wherein the fluid is a gas.  
     
     
         27 . The method according to  claim 25 , wherein the fluid is a liquid.  
     
     
         28 . The method according to  claim 27 , further comprising: 
 solidifying the liquid after injecting into the inflated cell.    
     
     
         29 . The method according to  claim 24 , wherein the fluid is evacuated until an interior of the cells has a gas pressure substantially similar to an ambient pressure external to the cells.  
     
     
         30 . The method according to  claim 25 , wherein the other fluid is injected into the cells until an interior of the cells has a gas pressure substantially similar to an ambient pressure external to the cells.  
     
     
         31 . The method according to  claim 15 , wherein forming the cells of uncured resin comprises: 
 feeding the uncured resin through a plurality of resin flow apertures in a plate.    
     
     
         32 . The method according to  claim 15 , wherein all of the cells are formed of a similar size.  
     
     
         33 . The method according to  claim 15 , wherein curing the resin comprises exposing the resin to at least one of ultraviolet radiation, heat, visible light, an electron beam, and microwave radiation.  
     
     
         34 . An apparatus for creating a structure comprising a plurality of cells of cured resinous material, the apparatus comprising: 
 a plurality of resin flow apertures arranged to permit cells formed at one aperture to contact cells formed at directly adjacent apertures; and    a resin flow control member arranged in each resin flow aperture and operable to control a flow of resin from the resin flow apertures.    
     
     
         35 . The apparatus according to  claim 34 , further comprising: 
 a liquid injection port arranged in each resin flow aperture for injecting liquid into a cell of uncured resin flowing out of the resin flow aperture to inflate the cell; and    a liquid flow control member operable to control a flow of liquid through the port.    
     
     
         36 . The apparatus according to  claim 35 , wherein the liquid comprises gas.  
     
     
         37 . The apparatus according to  claim 35 , wherein the liquid comprises a fluid.  
     
     
         38 . The apparatus according to  claim 34 , further comprising: 
 a forming plate that the resin flow apertures are formed through.    
     
     
         39 . The apparatus according to  claim 34 , further comprising: 
 at least one cell-retaining member for retaining the cells after curing of the resinous material.    
     
     
         40 . The apparatus according to  claim 34 , further comprising: 
 a source of energy for curing the uncured resin.    
     
     
         41 . The apparatus according to  claim 40 , wherein the energy source comprises at least one of a source of ultraviolet radiation, a heat source, a source of visible light, an electron beam source, and a source of microwave radiation.  
     
     
         42 . The apparatus according to  claim 34 , wherein the resin flow control member comprises a shutter valve.  
     
     
         43 . The apparatus according to  claim 34 , wherein a position of the resin flow aperture is alterable.  
     
     
         44 . The apparatus according to  claim 34 , wherein the apparatus form cells having a substantially uniform size.  
     
     
         45 . A structure comprising: 
 a plurality of groups of cells of cured resinous material, each group of cells being joined to at least one other group of cells and each cell being joined to at least one other cell.    
     
     
         46 . The structure according to  claim 45 , wherein the cells in each group are coplanar.  
     
     
         47 . The structure according to  claim 45 , wherein the cells within each group have a uniform size.  
     
     
         48 . The structure according to  claim 45 , wherein the cells among the groups have a uniform size.