Disclosed embodiments relate to trays typically comprising a composite internal structure, a thermoplastic frame typically located about the composite internal structure, and two cover sheets forming the upper and lower tray surfaces. The composite internal structure may be a corrugated composite structure in some embodiments. In other embodiments, the composite internal structure may comprise a series of composite elements (which might act a beams or struts). The cover sheets may comprise thermoplastic material, and in some embodiments, the cover sheets may comprise composite material (for example the same as for the corrugated composite structure). In some exemplary embodiments, the thermoplastic frame and the composite internal structure may have the same thermoplastic material, and they may be joined together to have a plurality of homogeneous connective attachments.

A fiber composite material component has fiber bundles and a matrix of thermoplastic and/or thermosetting material. The fiber bundles are arranged such that they form a profile. Bracing structures are arranged between the fiber bundles. At least two fiber bundles are arranged in a skewed manner with respect to one another and at least one cavity is formed in the region of the intersection of the skewed fiber bundles. Furthermore, a method for producing a fiber composite material component having fiber bundles and a matrix of thermoplastic and/or thermosetting material, is provided.

A plastics molding process is provided in which a first (2) and a second plastic part (3) are molded such that a contact surface is formed between the two parts. The first part (2) is molded firstly and, while at least the contact surface is still in a liquid or plastic state, an attachment promoting powder (16) that is compatible with, and has the characteristic of attaching to, the plastic of the first part (2), is applied to it. Thereafter, the second part (3) is molded so as to contact the first part at the contact surfaces such that as it solidifies, it attaches to the attachment promoting powder (16) and thereby to the first part (2). The second part (3) may be a plastic foam filling for a hollow first part (2). The attachment promoting powder (16) may be a suitable grade of diatomaceous earth or a natural or synthetic equivalent.

A tool for fabrication of a thermoplastic panel includes a sealed vessel, a membrane and a heater. The sealed vessel defines a volume. The sealed vessel includes first and second fluid ports. The membrane is disposed within the volume to define first and second chambers. The first chamber receives a skin and a core of the thermoplastic panel. The first chamber selectively applies a first fluidic pressure to the skin and the core in response to receiving a first fluid via the first fluid port. The membrane abuts a major surface of the thermoplastic panel. The second chamber selectively applies a second fluidic pressure to the membrane in response to receiving a second fluid via the second fluid port. The heater selectively directs heat toward the first chamber. A method for fabrication of the thermoplastic panel is provided. Various examples of thermoplastic panels are also provided.

An additive system for use in a polymeric formulation (plastic) that includes a plurality of visually differentiable elongated streaks contained in a mono-colored base, the visually differentiable elongated streaks are composed of a pigmented material having a random pattern and elongated due to the manufacturing process. The visually differentiable streaks are composed of at least two colors, each having a pigment shade visually differing from one another. The visually differentiable streaks are elongated and randomized during the manufacturing process to resemble the elongated markings present in natural materials such as marble or wood. The visually differentiable markings can be utilized in various color combinations to make lightweight useful articles having a pleasing aesthetic appearance.

A resin panel includes a first structure and a second structure stacked on each other. The structures includes reference surfaces that serve as the front surface and the back surface of the resin panel respectively. Each of the structures includes a plurality of protrusions protruding inwardly from the reference surface. The protrusions of the structure face the protrusions of the other structure each other. Jutting portions of linear shape are formed between adjacent protrusions of each of the structures. The structures are joined such that apical portions of the protrusions of each structure abut one another.

Hollow wall curable and cured composite tubes for improving performance in sports shafts, lightweight applications, and lightweight structural members, are described herein and include: a constituent tube, for forming the hollow wall composite tube, that comprises an evacuable flexible core component on which to wind or braid filaments or fabric, and at least one braid filament or at least one fabric for providing a reinforcing fiber matrix for saturation with an epoxy material, spirally wrapped, applied or braided on the flexible core component. Methods for producing and using the same are also disclosed herein.

Sandwich-structured noise-attenuating and/or structural panels and methods of manufacturing such panels using ultrasonic welding are described. The method includes: receiving a backing member, a sheet and a cellular structure; assembling the cellular structure between the backing member and the sheet; and ultrasonically welding the backing member and the sheet together.

A process for manufacturing an acoustic panel including at least one acoustically resistive layer, at least one cellular structure and a reflective wall. The process includes steps of depositing the parts of the acoustic panel made of thermosetting composite, depositing a film made of thermoplastic resin that is miscible with the thermosetting composite at the polymerization temperature of the thermosetting composite, polymerizing the parts of the acoustic panel made of thermosetting composite, and depositing and consolidating at least one layer made of thermoplastic composite against the film made of thermoplastic resin in order to form the reflective wall.

A method for producing a plastic board with an upper side 1, an underside 2 and at least one edge surface 3 by an injection-molding technique, and also a corresponding plastic board are provided. In the method, a first half 6, which forms at least the upper side of the plastic board, and a second half 7, which forms at least the underside of the plastic board, are injection-molded. Then, the first half and the second half are joined together in order to form a plastic board with an upper side and an underside. The two halves being formed in such a way that at least one cavity forms between the halves when they are joined together. The two halves are fixed onto one another, preferably by molding on a connecting component 5 of plastic.