Hex-D/T Honeycomb

Superstructure U.S. Patent 7,208,063

Honeycomb Structures
For years, the aerospace and defense industries have utilized
honeycomb products for their low weight and high-strength
properties. In recent years, engineers involved in the automotive,
marine and construction fields have shown interest in using
honeycomb sandwich-structures as well.
A number of metallic and non-metallic materials are used to
produce these honeycomb structures. Since most metallic
honeycomb structures are made of aluminum, they are prone
to corrosive damage caused by trapped moisture. The materials
used to make non-metallic honeycomb structures include
fiberglass, graphite, thermoplastics, Nomex (a non-flammable,
aramid fiber paper), Kevlar (an aramid fiber) and several other
specialty materials. These non-metallic resources can be very
high in cost and may not meet the engineering specifications
required by the particular application.
ARDLs Hex-D/T Honeycomb Superstructure
ARDLs Hex-D/T structural reinforcement design enables the
properties of a celled, honeycomb structure to be enhanced.
This is made possible by an inner and outer, double-walled cell
that behaves in a way such that the inner cell reinforces the outer
cell and vice versa. These cells are located on a base honeycomb
sandwich panel in a hexagonal manner, structurally maximizing
the design. (U.S. Patent 7,208,063)
The technology has broad potential for future aircraft applications. The Air Force is considering supersonic
vehicles that have unique structural requirements. Aerodynamic performance constraints drive the design of
these vehicles toward longer, sleeker configurations with thin fuselages, wings and tails (i.e. Concord and SR7l). The design of future high-speed aircraft will continue to be driven by the desire to significantly reduce the
structural weight of the aircraft while maintaining or increasing structural strength and stiffness.
ARDLs Hex-D/T honeycomb superstructure technology exhibits double the structural stiffness of
conventional cores at the same core weight. This allows for thinner, lower weight, structural designs.

Unstabilized Core, Normalized Data Comparison

Property
Density (Pcf)
Bare Compressive Strength (psi)
Plate Shear (psi)
Impact (psi)

Hex-T (ARDL, Inc.)

HRP

12.7

4.5

282% Increase

289.0

113.0

256% Increase

80.0

74.0

108% Increase

158.0

117.0

135% Increase

Rubber. Plastic. Latex.

% Change

Hex-D/T Honeycomb
Superstructure U.S. Patent 7,208,063 (cont.)
ARDLs Hex-D/T Honeycomb Superstructure Also Exhibits the Following Advantages:
Ability to Reinforce in Response to Stress Peaks
(Flexibility in Design)
Ballistic Resistant
Corrosion Resistant
Costs Less to Make than Specialty-Material
Based Honeycomb Structures
Enhances Properties of Celled Structure
(Impact, Shear, Compression, etc.)
High Energy Absorbing Capacity
High Modulus
High Stiffness
Low Weight

Machining / Forming
Manufacturability
Moisture Resistant
Multi-Solution Product
PCF Flexibility (Optimum Placement of Tubes )
Shock Mitigation Properties
Stronger Core-Skin Bond Due to
Larger Surface in Contact with Facing
Suitable for Various Engineering Requirements
Superior Resistance to Impact Damage
Support Against Damage Propagation by Containment
of Damage within Superstructure

These characteristics are the foundation for this honeycomb superstructure that has better performance and added durability.
This double-walled, repeated structure can be manufactured using a forming technique or a corrugated joining process where
the final shape of the inner and outer cells can be an ellipse/circle/polygon. It is the way the double-walled cells are organized
within the hexagonal superstructure that causes ARDLs Hex-D/T honeycomb core to exhibit such unique properties.
Unstabilized Honeycomb Core Plate Shear Data
Unstabilized Honeycomb Core Plate Shear Data
Ultimate
Force
vs Deflection
Ultimate
Force
vs. Deflection
12000
HexT-L

11000

HexT-W

10000
9000

Load (Lbf)

8000

Hex-T (W) 10150 psi

7000

1/4-HRP Paper (W) 2470 psi

3/16-HRP Paper 3227 psi

6000
Aluminum

5000

Aluminum 3903 psi

1/4 -HRP-L

4000

Hex-T (L) 12072 psi

1/4-HRP Paper (L) 3995 psi

3/16-HRP

3000
2000
1000

1/4-HRP-W

0
0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0.09

0.1

0.11

0.12

0.13

0.14

0.15

0.16

0.17

Deflection (in)

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