초록 ▼

A surface structure including a skin (13) a build-up (18) and a backing (20). A skin is formed and a build-up layer is applied to the skin. In one embodiment, gas pressure is applied to form the skin in a single-sided die. A nozzle on a five-axis arm then applies resin to the skin in a selected patt

A surface structure including a skin (13) a build-up (18) and a backing (20). A skin is formed and a build-up layer is applied to the skin. In one embodiment, gas pressure is applied to form the skin in a single-sided die. A nozzle on a five-axis arm then applies resin to the skin in a selected pattern. The selected pattern may form a hexagonal "honeycomb" cell structure, for example, to support the skin and may transition to a columnar cell structure for better crush resistance. The hexagonal-to-columnar structure provides superior crush resistance in automotive body panels, for example, and improved solar energy concentration in solar energy applications.

대표청구항 ▼

1. An article of manufacture comprising:a skin having a surface; a build-up material dispensed onto the surface of the skin to form a selected pattern of the build-up material, the selected pattern having a plurality of walls defining voids to form a build-up, the build-up being directly bonded to t

1. An article of manufacture comprising:a skin having a surface; a build-up material dispensed onto the surface of the skin to form a selected pattern of the build-up material, the selected pattern having a plurality of walls defining voids to form a build-up, the build-up being directly bonded to the skin without an intermediary adhesive material disposed between the build-up and the skin; and a backing conformed to and directly bonded to the build-up without a second intermediary adhesive material disposed between the build-up and the backing, the skin, the build-up, and the backing forming a unitary surface structure wherein the walls extend longitudinally from the skin toward the backing, separating the skin from the backing so as to provide tensile strength to resist deformation of the unitary surface structure.