Construction of large sandwich structures

Claim 2

A composite structure having a metal panel comprising first and second parallel plates having opposing faces, a corrugated metal stiffener sandwiched between said plates and having a plurality of parallel corrugations defining peaks and troughs, each corrugation having an end, said first and second plates being secured to the peaks and troughs, respectively, of said stiffener by weld lines extending along the peaks and troughs, said panel being assembled to a like panel with the corrugations of both panels aligned end-to-end, with straight edges of said first plates opposing one another, and with straight edges of said second plates opposing one another: wherein said straight edge of each first plate extends parallel to and forwardly of a plane containing the ends of the corrugations of the respective panel, and said straight edge of each second plate extends parallel to and rearwardly of said plane, and (a) a butt weld joins said first plate edges (b) a corrugated insert piece is joined at each of said opposing faces by butt welds to the ends of the corrugations on the respective panels and (c) a plate insert is butt-welded at parallel edges thereof to said straight edges of said second plates.

Claim 3

A panel assembly as claimed in claim 1 in which said corrugated insert piece includes peaks and valleys, and welds along the peaks and valleys of said corrugated insert piece.

Claim 4

A composite structure having a metal plane comprising first and second parallel plates having opposing faces, a corrugated metal stiffener sandwiched between said plates and having a plurality of parallel corrugations defining peaks and troughs, said first and second plates being secured to the peaks and troughs, respectively, of said stiffener by weld lines extending along the peaks and troughs, said panel being assembled to a like panel with straight edges of said first plates opposed to one another and with straight edges of said second plates opposed to one another, wherein opposed straight edges of said first parallel plates are spaced forwardly of opposed straight edges of said second parallel plates, and (a) a butt weld joins the first parallel plate opposed edges (b) a plate insert is butt-welded at parallel edges thereof to the respective opposed straight edges of the second parallel plates.

Claim 5

A composite structure having a metal plane comprising first and second parallel plates having opposing faces, a corrugated metal stiffener sandwiched between said plates and having a plurality of parallel corrugations defining peaks and troughs, said first and second plates being secured to the peaks and troughs, respectively, of said stiffener by weld lines extending along the peaks and troughs, said panel being assembled to a like panel with straight edges of said first plates opposed to one another and with straight edges of said second plates opposed to one another, wherein opposed straight edges of said first parallel plates are spaced forwardly of opposed straight edges of said second parallel plates, and (a) a butt weld joins the first parallel plate opposed edges (b) a plate insert is butt-welded at parallel edges thereof to the respective opposed straight edges of the second parallel plates.

Claim 6

A composite metal panel having two faces and consisting of: a first metal plate of at least 1 mm in thickness; a stiffener plate of at least 1 mm in thickness, said stiffener plate being configured with a plurality of parallel corrugations constituting peaks and troughs, wherein said corrugations have ends and each of said peaks and troughs has a center, said stiffener plate being welded to the first metal plate by laser welds extending along said troughs, through the thickness of the stiffener plate and into the first metal plate; and a second metal plate of at least 1 mm in thickness, said second metal plate also being welded to the stiffener plate by laser welds extending in parallel lines along the second metal plate, through the thickness thereof, and into and along said peaks of the stiffener plate; wherein (a) a straight end edge of said first plate is transverse to the corrugations and is parallel to and spaced forwardly of a plane containing the ends of the corrugations, and a straight end edge of said second plate is transverse to the corrugations and is parallel to and spaced rearwardly of said plane and (b) another straight edge of said first plate extends substantially along the center of a trough in a corrugation and another straight edge of said second plate extends substantially along the center of a peak in a corrugation.

Claim 7

A composite metal panel having two faces and consisting of: a first metal plate of at least 1 mm in thickness; a stiffener plate of at least 1 mm in thickness, said stiffener plate being configured with a plurality of parallel corrugations constituting peaks and troughs, wherein said corrugations have ends and each of said peaks and troughs has a center, said stiffener plate being welded to the first metal plate by laser welds extending along said troughs, through the thickness of the stiffener plate and into the first metal plate; and a second metal plate of at least 1 mm in thickness, said second metal plate also being welded to the stiffener plate by laser welds extending in parallel lines along the second metal plate, through the thickness thereof, and into and along said peaks of the stiffener plate; wherein (a) a straight end edge of said first plate is transverse to the corrugations and is parallel to and spaced forwardly of a plane containing the ends of the corrugations, and a straight end edge of said second plate is transverse to the corrugations and is parallel to and spaced rearwardly of said plane and (b) another straight edge of said first plate extends substantially along the center of a trough in a corrugation and another straight edge of said second plate extends substantially along the center of a peak in a corrugation.