Method of making energy absorbing backshell

Abstract

An energy absorbing backshell including a non-metallic core, a non-metallic casing surrounding the non-metallic core, a tube on the top surface of the non-metallic core and non-metallic casing.

1 . A method of forming an energy absorbing backshell comprising the steps of:
 forming a non-metallic casing surrounding a non-metallic core;   positioning a tube on a self-expanding foam layer on a top surface of the non-metallic core; and   affixing the tube on the top surface of the non-metallic core and non-metallic casing.   
     
     
         2 . The method of  claim 1  including the step of adhering the non-metallic core to the non-metallic casing by an adhesive. 
     
     
         3 . The method of  claim 1  wherein a cross-section of the non-metallic core is honeycomb shaped. 
     
     
         4 . The method of  claim 1  wherein the non-metallic core is made of a plurality of thin composite panels. 
     
     
         5 . The method of  claim 1  including the step of affixing a top surface of the non-metallic casing to the tube by a filler material. 
     
     
         6 . The method of  claim 1  wherein the tube is a bent metallic tube. 
     
     
         7 . The method of  claim 1  wherein the tube includes a curved back side that is connected to a straight side such that the curved side is opposite the straight side. 
     
     
         8 . The method of  claim 1  wherein the tube includes a first curved portion connected to an end of a straight side and a second curved portion connected to an opposite end of the straight side. 
     
     
         9 . The method of  claim 8  wherein the first curved portion and the second curved portion are substantially formed as U shaped. 
     
     
         10 . The method of  claim 1  further comprising the steps of:
 forming a structural support member extending from an inner portion of a first side of the backshell to an inner portion of a second side of the backshell; 
 securing the structural support member with the backshell; 
 positioning a structural support base portion extending around the periphery of a lower portion of the backshell; and 
 securing the structural support base portion with the backshell for absorption of larger impact forces. 
 
     
     
         11 . The method of  claim 10  wherein the first side is opposite the second side. 
     
     
         12 . The method of  claim 10  wherein the structural support base portion includes an extension portion that extends beyond an edge of the backshell.