A component, including a part, comprising a honeycomb-like structure formed from at least a seamless resin-infused fiber composite material. The honeycomb-like structure includes a first plurality of cells, and a second plurality of cells, different than the first plurality of cells.

In a process for manufacturing a catalytic converter component, a ceramic unit is used that has been prepared by extruding green ceramic product through a die to form an extrusion having a honeycomb substrate structure in which tubular passages extend along the extrusion, the passages bounded by walls dividing adjacent passages from one another. The unit is obtained by cutting off a length of the extrusion and curing and firing it. The process further comprises, following the firing, injecting a mixture of a mastic component and a particulate metal component from an end of the ceramic unit into selected ones of the cells so as to block the selected cells over at least a part of the lengths thereof while maintaining all of the walls of the ceramic unit, and curing the injected material to render the injected material solid.

A gaseous emissions treatment component is made by extruding a green ceramic mix through a die to form an extrusion having a honeycomb substrate with elongate cells extending its length and with the cells bounded by walls dividing adjacent cells from one another. Molten metal for use in induction heating of the component is placed in selected cells and is solidified by cooling.

In one aspect, there is a method of making a composite skin for a tiltrotor aircraft including providing a first skin in a mold, the first skin having a periphery defined by a forward edge, an aft edge, and outboard ends; providing a plurality of honeycomb panels having an array of large cells onto the first skin, each cell having a width of at least 1 cm; assembling the plurality of honeycomb panels along the longitudinal axis of the first skin to form a honeycomb core having an outer perimeter within the periphery of the first skin; positioning a second skin onto the honeycomb core, the second skin having an outer perimeter within the periphery of the first skin; and curing an adhesive to create a bond between the first skin, the honeycomb core, and the second skin to form a composite skin.

Presented are fiber-reinforced polymer (FRP) sandwich structures, methods for making/using such FRP sandwich structures, and motor vehicles with a vehicle component fabricated from a compression molded thermoset or thermoplastic FRP sandwich structure. A multidimensional composite sandwich structure includes first and second (skin) layers formed from a thermoset of thermoplastic polymer matrix, such as resin or nylon, filled with a fiber reinforcing material, such as chopped carbon fibers. A third (core) layer, which is encased between the first and second skin layers, is formed from a thermoset/thermoplastic polymer matrix filled with a fiber reinforcing material and a filler material, such as hollow glass microspheres. The first, second and third layers have respective rheological flow properties that are substantially similar such that all three layers flow in unison at a predetermined compression molding pressure. These layers may be formed from the same thermoset/thermoplastic polymer material, and include the same fiber reinforcing material.

A composite acoustic liner has a septumized cellular core. Septa are installed in the core as the individual core cells are being formed. Individual tools are used to both form the cells of the core and index the septa within the cells. The septa and the cellular core are cocured.

The present disclosure relates to a process of manufacturing a multicellular structure comprising interconnected cells, wherein the process comprises: a) providing a polymerizable precursor of a polymeric material, wherein the polymerizable precursor comprises a reactive monomer mixture; b) providing a mold comprising precursor structures of the multicellular structure; c) optionally, heating at least one the reactive monomer mixture or the mold; d) incorporating the reactive monomer mixture into the precursor structures of the multicellular structure thereby substantially filling up the precursor structures of the mold, wherein the reactive monomer mixture has a viscosity of no greater than 10,000 mPa-s when incorporated into the precursor structures of the multicellular structure and when measured according to the viscosity test method defined in the experimental section; e) polymerizing the polymerizable precursor of the polymeric material into the precursor structures of the mold; and f) demolding the multicellular structure formed by polymerizing the polymerizable precursor of the polymeric material. According to another aspect, the present disclosure relates to a multicellular structure obtainable by the process as described above. In another aspect, the present disclosure relates to the use of a multicellular structure as described above for industrial applications.

A method and system for manufacturing a conical shaped acoustic structure. A sheet of acoustical material is cut to form individual pieces using a cutter system. Each individual piece in the individual pieces has a flat pattern for the conical shaped acoustic structure. An individual piece is positioned around a mandrel with a conical shape using an actuator system. Two edges of the individual piece are positioned for joining. The two edges of the individual piece positioned around the mandrel are joined to form the conical shaped acoustic structure.

The invention relates to a method for producing a reinforcement section in a preferably plate-shaped workpiece, wherein the workpiece has a core layer, a first cover layer and a second cover layer. In particular, such a workpiece may be a lightweight building board. Provision is made therein for a pasty, thermosetting mass to be introduced into an opening by way of the nozzle, while the nozzle and/or the workpiece moves at least temporarily during the release of the mass.

In a process for manufacturing a catalytic converter component, a ceramic unit is used that has been prepared by extruding green ceramic product through a die to form an extrusion having a honeycomb substrate structure in which tubular passages extend along the extrusion, the passages bounded by walls dividing adjacent passages from one another. The unit is obtained by cutting off a length of the extrusion and curing and firing it. The process further comprises flowing insulation material from one end of the unit into selected ones of the elongate passages, the insulating material then being cured. The passages are selected so that the cured insulation material forms an internal thermal insulating barrier between a core zone and a radially outer zone of the unit. Passages in the inner and outer zones are free of insulation material and the honeycomb structure walls include walls crossing the insulating barrier.