Method of brazing honeycomb sandwich with edge members and inserts

Claim 1

A METHOD OF BONDING TOGETHER AN INTEGRATED SANDWHICH STRUCTURE THAT INCLUDES SECTIONS OF THIN GAGE CELLULAR CORE ARRANGED IN COMBINATION WITH HEAVY GAGE REINFORCING MEMBERS ASSEMBLED WITH THE EDGES OF THE CORE WALLS PERPENDICULAR TO AND CONTACTING FACING SURFACES OF PANELS POSITIONED ON EACH SIDE OF SAID COMBINATION, SAID REINFORCING MEMBERS ALSO HAVING SURFACE THEREOF CONTACTING SAID FACING SURFACES OF SAID PANELS, WHICH COMPRISES: INSERTING A FUSIBLE MATERIAL BETWEEN ALL CONTACTING SURFACE OF SAID COMBINATION, SEALING SAID COMBINATION TO BE BONDED WITHIN MATING HALVES OF A THIN WALLED FLEXIBLE METALLIC ENVELOPE THE INTERIOR OF WHICH IS SHAPED TO CONFORM TO THE EXTERIOR SHAPE OF SAID SANDWHICH COMBINATION, PURGING THE ENVELOPES INTERIOR OF ATMOSPHERE, INJECTING NON-OXIDIZING GAS INTO SAID ENVELOPE INTERIOR, THE PRESSURE OF SAID NON-OXIDIZING GAS BEING LESS THAN ATMOSPHERIC, GRADUALLY HEATING SAID ENVELOPE BY CONTROLLED DISCRETE TEMPERATURE STAGES SO THAT SAID HEAVY GAGE MEMBERS AND CELLULAR CORE ARE MAINTAINED AT SUBSTANTIALLY THE SAME ELEVATED TEMPERATURE AT ALL TIMES TO REDUCE WRAPAGE THEREBETWEEN, WHILE SAID EVELOPE IS VERTICALLY POSITIONED SO THAT SAID CORE WALLS ARE HORIZONTAL RELATIVE TO SAID FACING SURFACE OF SAID PANELS, SAID HEATING CONTINUING TO A SUFFICIENTLY ELEVATED TEMPERATURE TO MELT SAID FUSIBLE MATERIAL WHILE SAID CONTACTING SURFACES ARE IN SAID VERTICAL POSITION SO THAT THE CORE WALLS DEFINE FLOW CONTROLLING DAMS TO INDUCE CONTROLLED UNIFORM DISTRIBUTION OF SAID FUSIBLE MATERIAL BETWEEN THE FACING SURFACES OF SAID PANELS AND CONTACTING EDGES AND SURFACES OF SAID COMBINATION, REMOVING SAID ENVELOPE FROM HEAT, SIMULTANEOUSLY COMPRESSING THE BONDED SURFACES OF SAID COMBINATION TOGETHER AND COOLING SAID EVELOPE IN CONTROLLED DISCRETE STAGES, AND REMOVING SAID COMBINATION FROM SAID ENVELOPE.

Claim 2

A METHOD OF BONDING TOGETHER AN INTEGRATED SANDWHICH STRUCTURE THAT INCLUDES SECTIONS OF THIN GAGE CELLULAR CORE ARRANGED IN COMBINATION WITH HEAVY GAGE REINFORCING MEMBERS ASSEMBLED WITH THE EDGES OF THE CORE WALLS PERPENDICULAR TO AND CONTACTING FACING SURFACES OF PANELS POSITIONED ON EACH SIDE OF SAID COMBINATION, SAID REINFORCING MEMBERS ALSO HAVING SURFACE THEREOF CONTACTING SAID FACING SURFACES OF SAID PANELS, WHICH COMPRISES: INSERTING A FUSIBLE MATERIAL BETWEEN ALL CONTACTING SURFACE OF SAID COMBINATION, SEALING SAID COMBINATION TO BE BONDED WITHIN MATING HALVES OF A THIN WALLED FLEXIBLE METALLIC ENVELOPE THE INTERIOR OF WHICH IS SHAPED TO CONFORM TO THE EXTERIOR SHAPE OF SAID SANDWHICH COMBINATION, PURGING THE ENVELOPES INTERIOR OF ATMOSPHERE, INJECTING NON-OXIDIZING GAS INTO SAID ENVELOPE INTERIOR, THE PRESSURE OF SAID NON-OXIDIZING GAS BEING LESS THAN ATMOSPHERIC, GRADUALLY HEATING SAID ENVELOPE BY CONTROLLED DISCRETE TEMPERATURE STAGES SO THAT SAID HEAVY GAGE MEMBERS AND CELLULAR CORE ARE MAINTAINED AT SUBSTANTIALLY THE SAME ELEVATED TEMPERATURE AT ALL TIMES TO REDUCE WRAPAGE THEREBETWEEN, WHILE SAID EVELOPE IS VERTICALLY POSITIONED SO THAT SAID CORE WALLS ARE HORIZONTAL RELATIVE TO SAID FACING SURFACE OF SAID PANELS, SAID HEATING CONTINUING TO A SUFFICIENTLY ELEVATED TEMPERATURE TO MELT SAID FUSIBLE MATERIAL WHILE SAID CONTACTING SURFACES ARE IN SAID VERTICAL POSITION SO THAT THE CORE WALLS DEFINE FLOW CONTROLLING DAMS TO INDUCE CONTROLLED UNIFORM DISTRIBUTION OF SAID FUSIBLE MATERIAL BETWEEN THE FACING SURFACES OF SAID PANELS AND CONTACTING EDGES AND SURFACES OF SAID COMBINATION, REMOVING SAID ENVELOPE FROM HEAT, SIMULTANEOUSLY COMPRESSING THE BONDED SURFACES OF SAID COMBINATION TOGETHER AND COOLING SAID EVELOPE IN CONTROLLED DISCRETE STAGES, AND REMOVING SAID COMBINATION FROM SAID ENVELOPE.