Layers of plies of composite material are laid on a convex tool surface. A first layer is placed with a first ply of a first section having a gap edge adjacent a gap edge of a first ply of a second section, the edges being parallel and a contraction distance from each other. A second layer is placed with a second ply of the first section having a gap edge adjacent a gap edge of a second ply of the second section, the edges being parallel and a contraction distance from each other, the second ply of the second section overlapping onto the first ply of the first section by a splice distance. Consolidation and curing cause contraction of the layers toward the tool, allowing the adjacent gap edges of each layer to be in close proximity or in contact after moving toward each other during the contraction.

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

A vehicle outer plate panel includes: a transparent resin plate that is formed into a prescribed shape through pressure molding and is attached to a vehicle so as to constitute an outer wall of a body; and a decorative layer that is formed on at least a part of the transparent resin plate through screen printing such that the transparent resin plate is decorated therewith. A method of producing an vehicle outer plate panel is also disclosed.

This document describes systems and processes for forming improved synthetic molded slabs suitable for use in living or working spaces (e.g., along a countertop, table, floor, or the like).

In one aspect, there is a composite skin for a tiltrotor aircraft including a first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; a second skin; and a honeycomb core disposed between the first skin and the second skin, the honeycomb core comprised of a plurality of honeycomb panels positioned along the longitudinal axis of the first skin, the plurality of honeycomb panels having an array of large cells, each cell having a width of at least 1 cm; wherein the second skin and the honeycomb core have an outer perimeter within the periphery of the first skin.

A foam-based expansion joint seal system packaging which facilitates transport and reduces the need for internal splices which includes laterally-flexible packaging bodies. The packaging bodies may include flutes, corrugations or prisms on their exterior to enable lateral bending of the foam-based expansion joint seal system packaging, even into coils.

Here are described composite panels comprising at least one integrated or embedded electrical circuit, their methods of manufacturing and their use in the aeronautic and aircraft industries. Also described are aircraft components comprising the composite panel as defined herein.

A system and method for fabricating large composite fuselages or other vehicle structures, in which the composite structure is fabricated and cured as on a tool, segmented and removed from the tool without disassembling the tool, and then reassembled off the tool to reform the large structure. The tool includes mandrel segments attached to a substructure. The attachments may be moveable to accommodate differential expansion and contraction during curing, and the tool may be rotatable to facilitate access. A composite material of resin and synthetic fibers is applied over the mandrel segments to fabricate the structure on the tool. Caul plates are secured over the composite material, and the composite material is cured on the tool. The resulting structure is cut into part segments which are then removed from the tool, and the part segments are joined to reassemble the large composite structure off the tool.

A method of manufacturing a cured composite structure includes placing a radius filler element into a radius cavity extending along a length of a composite base member. The radius filler element is formed of a permeable material. The method also includes absorbing resin from the composite base member into the permeable material of the radius filler element. The method additionally includes curing or solidifying the resin in the radius filler element and in the composite base member to form a cured composite structure in which the resin bonds the radius filler element to the composite base member.

A method of forming a reinforced panel may include engaging a reinforcement component having a faying surface with a first portion of a heated press, engaging an uncured panel component with an opposing second portion of the press, the panel component having a faying surface complementarily-configured with respect to the faying surface of the reinforcement component, treating the faying surface of the reinforcement component such that the faying surface is active for co-bonding with respect to the panel component, actuating the press to direct the first and second portions of the press toward each other, such that the faying surfaces are complementarily engaged under pressure; and heating the first and second portions of the press to a curing temperature associated with the panel component to substantially simultaneously co-bond the faying surfaces of the reinforcement component and the panel component together, cure the panel component, and form the reinforced panel.