A method is proposed for producing a functional material, wherein in at least one mixing step (14) a pulverized rigid foam (16) and at least one binding agent (18) are mixed to form a raw mass, and wherein in at least one pressing step (22) the raw mass is pressed to form the functional material, the method proceeding in a continuous manner at least from the mixing step (14) up to and including the pressing step (22).

A caul body for forming a composite structure comprises a laminate having at least one carbon layer and at least one silicone layer. The at least one silicone layer defines an outer surface of the laminate. The laminate has a first region and a second region. A thickness of the at least one carbon layer in the first region is greater than a thickness of the at least one carbon layer in the second region. The first region has a hardness value greater than a hardness value of the second region.

A caul body for forming a composite structure comprises a laminate having at least one carbon layer and at least one silicone layer. The at least one silicone layer defines an outer surface of the laminate. The laminate has a first region and a second region. A thickness of the at least one carbon layer in the first region is greater than a thickness of the at least one carbon layer in the second region. The first region has a hardness value greater than a hardness value of the second region.

A method of manufacturing a self-supporting, monolithic fuselage body, including engaging peripheral mandrel sections around at least one central mandrel section, placing uncured composite material on the mold surface, curing the composite material on the mold surface, and sliding the central mandrel section(s) out of engagement with the peripheral mandrel sections and disengaging the peripheral mandrel sections from the cured composite material without collapsing the mandrel sections. The peripheral mandrel sections each include a shape-retaining core of a thermally insulating material and an outer layer on an outer surface of the shape-retaining core. The outer layer has a coefficient of thermal expansion within the range of variation of that of the coefficient of thermal expansion of the composite material. A mandrel for layup and cure of a predetermined composite material in the manufacture of a monolithic fuselage is also discussed.

To provide a resin molding mold capable of forming a resin molded product having embossing in which by controlling appearance of gloss, its texture is improved, and the resin molded product is prevented from occurrence of white blurring on the surface on which the molded embossing is formed. A resin molding mold in accordance with the present application is used for molding a resin molded product having embossing formed thereon. The resin molding mold includes a molding mold and a buffer layer formed on an inside mold surface of the molding mold. The buffer layer is formed by a mixture of a thermosetting resin and fine particles having substantially spherical shapes. The fine particles have a bulk specific gravity in a range from 0.4 g/ml or more to 0.9 g/ml or less, and on the surface of the buffer layer, a plurality of gloss adjusting convex portions having substantially spherical shapes derived from the fine particles are formed.

To provide a resin molding mold capable of forming a resin molded product having embossing in which by controlling appearance of gloss, its texture is improved, and the resin molded product is prevented from occurrence of white blurring on the surface on which the molded embossing is formed.

A resin molding mold in accordance with the present application is used for molding a resin molded product having embossing formed thereon. The resin molding mold includes a molding mold and a buffer layer formed on an inside mold surface of the molding mold. The buffer layer is formed by a mixture of a thermosetting resin and fine particles having substantially spherical shapes. The fine particles have a bulk specific gravity in a range from 0.4 g/ml or more to 0.9 g/ml or less, and on the surface of the buffer layer, a plurality of gloss adjusting convex portions having substantially spherical shapes derived from the fine particles are formed.

A method of manufacturing a self-supporting, monolithic fuselage body, including engaging peripheral mandrel sections around at least one central mandrel section, placing uncured composite material on the mold surface, curing the composite material on the mold surface, and sliding the central mandrel section(s) out of engagement with the peripheral mandrel sections and disengaging the peripheral mandrel sections from the cured composite material without collapsing the mandrel sections. The peripheral mandrel sections each include a shape-retaining core of a thermally insulating material and an outer layer on an outer surface of the shape-retaining core. The outer layer has a coefficient of thermal expansion within the range of variation of that of the coefficient of thermal expansion of the composite material. A mandrel for layup and cure of a predetermined composite material in the manufacture of a monolithic fuselage is also discussed.