Structural panel insert with honeycomb core

Abstract

A structural insert with a cellular core as a holder for filler materials, in combination with other dense or porous material types arranged in the structural insert, to achieve a desired shear strength and stiffness in desired locations. The insert having metal within any areas of open porosity and the insert capable of being used as a component in a composite system such as a light weight armor.

1 . A structural insert for a composite armor, comprising:
 an encapsulating barrier formed around a cellular structure, said cellular structure having a plurality of openings , said plurality of openings having oppositely faced sides between which said plurality of openings extend; and   a filler material disposed within at least one of said plurality of openings, said plurality of openings further comprising said encapsulating metal.   
     
     
         2 . A structural insert for a composite armor as in  claim 1 , further comprising a second filler material disposed in at least one of said plurality of openings, said first filler material and said second filler material in different openings. 
     
     
         3 . A structural insert for a composite armor as in  claim 1 , further comprising a second filler material disposed in at least one of said plurality of openings, said first filler material and said second filler material in the same openings. 
     
     
         4 . A structural insert for a composite armor as in  claim 1 , wherein a portion of said cellular structure is replaced by a second filler material , wherein said second filler material is porous, said porous material further comprising a metal infiltrated therein. 
     
     
         5 . A structural insert as in  claim 1 , wherein one or more of said structural inserts are arranged in a common plane, said common plane inserts further arranged in one or more stacked layers. 
     
     
         6 . A structural insert as in  claim 1  wherein said encapsulating metal barrier is continuous from the interior of said cellular structure to the periphery of said cellular structure. 
     
     
         7 . A structural insert as in  claim 1  further comprising first and second face sheets disposed on opposite sides of said cellular structure, said encapsulating metal barrier formed around said cellular structure and said face sheets. 
     
     
         8 . A structural insert for a composite armor as in  claim 1 , wherein a portion of said cellular structure is replaced by a second filler material, wherein said second filler material is a dense material. 
     
     
         9 . A structural insert for a composite armor as in  claim 5 , wherein said structural inserts arranged in a common plane have spacing therebetween. 
     
     
         10 . A structural insert for a composite armor as in  claim 5 , wherein said one or more stacked layers further comprise one or more dense materials disposed between said one or more stacked layers. 
     
     
         11 . A structural insert as in  claim 7 , further comprising a dense material layer, said dense material layer disposed between said first and second face sheets. 
     
     
         12 . A structural insert as in  claim 5 , further comprising one or more face sheets disposed on the top and bottom of said one or more stacked layers. 
     
     
         13 . A structural insert as in  claim 1 , wherein said filler material is a plurality of high volume hollow microspheres. 
     
     
         14 . A structural insert as in  claim 7 , wherein said first and second face sheet thickness precludes said cellular structure from bending. 
     
     
         15 . A structural insert as in  claim 14 , wherein said first and second face sheet thickness is from about 1/10 to ¼ the thickness of said cellular structure. 
     
     
         16 . A structural insert as in  claim 1 , wherein said encapsulating metal bonds said cellular structure and said filler material.