A honeycomb sandwich structure in which moisture absorption deformation can be sufficiently suppressed and a method for manufacturing the same are provided. The honeycomb sandwich structure includes: a honeycomb core having a recess in a mesh of a carbon fiber fabric; a pair of face plates; a resin layer which fills a part of the recesses; and a water-impermeable film which covers an exposed area including surfaces of the resin layer and the honeycomb core, wherein the recess includes an unfilled part, the unfilled part is a part of the recess that is closer to the opening of the recess, and the unfilled part is not filled with the resin layer.

A method of producing a core for a composite panel along a continuous production line is disclosed. The method includes the steps of providing a thermoplastic sheet of material onto the production line and vacuum forming the thermoplastic sheet of material into alternating pairs of matching shapes, providing the thermoplastic sheet of material with alternating pairs of matching shapes onto upper and lower conveyor belts that are operating at lower speeds than the production line causing the pairs of matching shapes to bunch up and form a honeycomb structure, and cutting the honeycomb structure into discrete sections with spaces therebetween. A plurality of reinforced plastic bands with gaps therebetween are provided and the honeycomb structure is aligned with the gaps. The plurality of reinforced plastic bands and the honeycomb structure are secured together.

Core structures for composite panels, aircraft including the same, and related methods. A core structure includes a core body defining a first body side, a second body side, and a plurality of core cells. Each core cell includes at least one cell wall and defines a tubular cell void. Each core cell includes a bulk region and a transition region. Each cell wall is flared within the transition region to increase a surface area of the first body side relative to an average transverse cross-sectional area of the core body. A composite panel includes a core structure with at least one laminate ply coupled to the first body side of a core body. A method of manufacturing a composite panel includes forming a core body via an additive manufacturing process and operatively attaching at least one laminate ply to the core body.

A honeycomb core includes carbon fiber having four or more different fiber directions, and when a ribbon direction is set as an X axis direction, a cell width direction is set as a Y axis direction, and a direction that is orthogonal to the ribbon direction and the cell width direction is set as a Z axis direction. A condition in which angles formed by the X axis direction and the respective fiber directions of the carbon fiber are set at 45 degrees, 0 degrees, 45 degrees, and 90 degrees is set as a reference condition. The respective fiber directions are rotated from the reference condition by a fixed rotation angle so that none of the fiber directions are parallel to the X axis direction.

In a transmission case mounted on a FF type vehicle, the transmission case includes a resin side cover formed at a front side of the vehicle. The resin side cover constitutes a vehicle front side surface section of an oil storage section configured to store oil in the transmission case, and includes a protrusion disposed above an oil surface of the oil stored in the oil storage section and protruding toward the front side of the vehicle to constitute the foremost section of the transmission case and a fragile section disposed between the protrusion and the oil surface of the oil and extending transversely in a lateral direction.

An anti-icing honeycomb core composite manufactured by forming an electromagnetic wave absorption layer by using dielectric fiber, molding the electromagnetic wave absorption layer into a honeycomb core structure by using a molded part including a first base, a second base, and an inner block, hardening the honeycomb core structure, and removing the molded part. The molding step includes first stacking, on the first base including a plurality of grooves in which the inner blocks each having a hexagonal column shape are able to be seated, a plurality of the inner blocks and a plurality of the electromagnetic wave absorption layers as the honeycomb core structure so that the electromagnetic wave absorption layer is disposed between the plurality of inner blocks, and second stacking covering the inner blocks and the electromagnetic wave absorption layers stacked on the first base with the second base having the same shape as the first base.

A method for continuously manufacturing a complex acoustic multi-element panel for an acoustic attenuation structure, the method including supplying a thermoplastic resin film at the entry of a stamping system including at least one pair of complementary cylinders, a heating of the thermoplastic resin film upstream of the entry of the stamping system, and a passage of the thermoplastic resin film between the at least one pair of complementary cylinders, the pair of complementary cylinders including a male cylinder with teeth radially protruding from the cylinder and a female cylinder with cavities on its radial surface, the cavities of the female cylinder being of shapes complementary to the shapes of the teeth of the male cylinder and a separation of the stamped film at the exit of the stamping system using a separator disposed at the exit of the stamping system between the stamped film and the female cylinder.

A load structure may include a panel having a core, and a coating of polyurethane around the core. The load structure may also have a layer of carpet or felt on at least a portion of a first side of the panel. The load structure may further include an over mold coating on a second side of the panel.

Embodiments disclosed herein relate to polymer resins having a first thermoset and one or more additional components (e.g., a second thermoset and/or a thermoplastic), composite laminates including the same, methods of making and using the same, and composite laminate structures including the same.

Cells of a composite cell array are cured by placing tool blocks in the cells and inserting thermally conductive elements in each of the tool blocks. The thermally conductive elements are convectively heated by a flow of hot air. The heated conductive elements conduct heat to the tooling blocks, which then conduct heat to the cells to cure the composite and adhesive.