Formed core sandwich structure and method and system for making same

Abstract

A method and apparatus for producing a metal core sandwich structure that is lightweight and many times stiffer than regular sheet metal, and which is easily formable into curved structures as well as structures having compound curves. In one embodiment, a formed metal core includes a plurality of cells comprising alternating front and rear projections extending outwardly in front of and behind a median plane, with each projection having a bonding surface area or land configured to be brazed or bonded with corresponding external metal sheets on both sides of the formed metal core. A plurality of micro-abrasions or indentations are formed on the bonding lands, allowing stronger brazing or bonding joints to be formed between the metal core and the external metal sheets by facilitating improved capillary action by the metal core during the brazing or bonding process.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] The present application is a continuation-in-part of U.S. application Ser. No. 11 / 285,096, filed on Nov. 22, 2005, entitled “Formed Metal Core Sandwich Structure and Method and System for Making Same” and the disclosures of which are herein incorporated by reference in their entirety.BACKGROUND OF THE INVENTION [0002] 1. Technical Field [0003] The present invention relates to metal sandwich sheet structures and, more particularly, to formable metal core sandwich sheet structures and methods and systems for manufacturing same. [0004] 2. Description of Related Art [0005] Metal core sandwich structures are known in the art. For example, U.S. Pat. No. 3,525,663 to Hale and U.S. Pat. No. 4,035,536 to Morrison both disclose metal sandwich structures having a formed metal core brazed to two outer metal sheets. However, it is believed that the structures disclosed by Hale and Morrison, and other similar conventional formed metal core sandwich s...

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