Complex shaped articles and method of manufacture

Abstract

Complex shaped articles and a method for their manufacture are disclosed. The complex shaped articles comprise a one piece, honeycomb core material that can be conformally shaped for aerodynamic and hydrodynamic movement having formed edges and an outer skin bonded to its top and bottom surfaces to protect and encase the honeycomb core material and provide a drag resistant surface. The method for manufacturing the disclosed complex shaped articles comprises: trimming, cutting and shaping a honeycomb core material to a desired size and shape; deforming the sized and shaped honeycomb core material; permanently setting the shape and contour of the sized and shaped honeycomb core material; affixing side edges to the shaped and contoured honeycomb core material; and, bonding a fiber reinforced resin to the top and bottom surfaces of the honeycomb core material.

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         17 . A complex aerodynamic and hydrodynamic article formed by a method, said method comprising: 
 (a) trimming a honeycomb material to a desired shape, said shape having a core with a top surface, a bottom surface and side edges;    (b) abutting said trimmed honeycomb core against an open mold, said mold having an open surface and a predetermined contour and shape;    (c) conforming said honeycomb core to the shape of said mold by applying pressure to said top surface of said trimmed honeycomb core;    (d) before removing said pressure and before removing said core from said mold cutting said conformed honeycomb core substantially parallel to the open surface of the mold, whereby said honeycomb has a thickness defined by the distance between the mold contour and the cut surface; and    (e) releasing said pressure so that said honeycomb forms a surface between opposed sides on the upper surface of said article, that is higher than at least one of said opposed sides.    
     
     
         18 . The article of  claim 17  wherein said article includes: 
 (a) a surface extending along its longitudinal axis from the front end to the rear end thereof; and  
 (b) a surface extending across its transverse axis between the opposed sides of said article wherein a convex surface is defined on the upper surface of said article.  
 
     
     
         19 . The article of  claim 17  wherein said article includes: 
 (a) a contoured, accurate shape on at least one opposed side thereof; and  
 (b) a contoured arc extending across its transverse axis between the opposed side of said article, wherein a convex arc is defined between said opposed sides on one surface of said article, and wherein said arc is significantly higher between said opposed sides and tapering there from across said transverse axis and along said longitudinal axis to a significantly flat shape on the other surface.  
 
     
     
         20 . The article of  claim 17  wherein said article includes: 
 (a) a contoured, accurate shape on at least two opposed sides thereof; and  
 (b) a contoured arc extending across its transverse axis between the opposed sides of said article wherein a convex arc is defined between said opposed sides on one surface of said article, and wherein said convex arc is significantly higher at one of said opposed sides and tapering there from across said transverse axis and along said longitudinal axis to a significantly lower height at the other of said opposed sides.  
 
     
     
         21 . The article of  claim 18  wherein said surface extending along its longitudinal axis is tapered.  
     
     
         22 . The article of  claim 18  wherein said surface extending along its longitudinal axis is rounded.  
     
     
         23 . The article of  claim 18  wherein said surface extending along its transverse axis is tapered.  
     
     
         24 . The article of  claim 18  wherein said surface extending along its transverse is rounded.  
     
     
         25 . The article of  claim 18  wherein the said surface along the transverse axis is symmetrical.  
     
     
         26 . The article of  claim 18  wherein the said surface along the longitudinal axis is symmetrical.  
     
     
         27 . The article of  claim 18  wherein a concave contour is defined on the lower surface.  
     
     
         28 . The article of  claim 18  wherein a convex contour is defined on the lower surface.  
     
     
         29 . The article of  claim 18  wherein a flat surface is defined on the lower surface.  
     
     
         30 . The article of  claim 20  wherein said contour extending along its longitudinal axis is tapered.  
     
     
         31 . The article of  claim 20  wherein said contour extending along its longitudinal axis is rounded.  
     
     
         32 . The article of  claim 20  wherein said contour extending along its transverse axis is tapered.  
     
     
         33 . The article of  claim 20  wherein said contour extending along its transverse axis is rounded.  
     
     
         34 . The article of  claim 20  wherein the contour along the transverse axis is symmetrical.  
     
     
         35 . The article of  claim 20  wherein the contour along the longitudinal axis is symmetrical.