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.

A method of forming a thermoplastic cellular structure includes positioning a lower surface of a trough of a first corrugated thermoplastic sheet against an upper surface of a crest of a second corrugated thermoplastic sheet; positioning a support against a lower surface of the crest of the second corrugated thermoplastic sheet; and pressing a thermoplastic welding element against an upper surface of the trough of the first corrugated thermoplastic sheet so that at least a portion of the lower surface of the trough of the first corrugated thermoplastic sheet melts and bonds to at least a portion of the upper surface of the crest of the second corrugated thermoplastic sheet.

A load ramp for a vehicle includes a corrugated layer that has a first surface and a second surface. A first layer is positioned adjacent to the first surface of the corrugated layer. A second layer is positioned adjacent to the second surface of the corrugated layer such that the corrugated layer is positioned between the first and second layers. A thickness of the load ramp can be in the range of about 10 mm to about 30 mm. A load capacity of the load ramp can be at least about 100 kg. A method of manufacturing the load ramp is also disclosed.

A panel for a nacelle of an aircraft propulsion assembly includes two skins and a cell structure provided with transverse partitions defining cells. The cell structure includes folds with at least one central part forming at least one part of at least one transverse partition and at least one peripheral part extending along at least one of the skins. A nacelle with such a panel is provided, as well as a method for manufacturing such a panel.

A fiber-reinforced resin composite includes a honeycomb core, a fiber-reinforced resin layer, and a protection layer. The honeycomb core includes a plurality of cells that are defined by partition walls and extend in an axial direction. The fiber-reinforced resin layer is disposed around the honeycomb core. The fiber-reinforced resin layer includes continuous fibers wound around the honeycomb core. The protection layer is interposed between the honeycomb core and the fiber-reinforced resin layer. The protection layer is configured to prevent rupture of the continuous fibers.

A method for continuously fabricating a composite sandwich structure includes the steps of: (1) moving a laminate, substantially continuously, through a preheating zone, wherein the laminate includes a first face sheet, a second face sheet and a core sandwiched between the first face sheet and the second face sheet; (2) preheating the laminate to a preforming temperature above a glass transition temperature of the laminate and below or equal to a crystalline melt temperature of the laminate as the laminate is being moved through the preheating zone; (3) moving the laminate, substantially continuously, through a consolidation zone; and (4) consolidating the laminate as the laminate is being moved through the consolidation zone to form a continuous length of the composite sandwich structure.

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 honeycomb-like cells, and a second plurality of honeycomb-like cells, different than the first plurality of honeycomb-like cells.

A unitary core panel for a composite sandwich structure includes a plurality of cell walls defining a plurality of core cells, the plurality of cell walls extending across a thickness of the core, the plurality of core cells including one or more defined structural nonuniformities resulting in nonuniform properties of the core panel. A method of forming a core panel for a composite sandwich structure includes determining structural requirements of the core panel, designing the core panel to satisfy the structural requirements with one or more local nonuniformities in the core panel, and manufacturing the core panel as a unitary core panel with the one or more local nonuniformities.

Some embodiments provide a core member for a composite panel that includes a hollow cell network structure, such as a honeycomb arrangement for example, and reinforced plastic strips positioned on a portion of the continuous honeycomb structure. The honeycomb structure and the solid plastic strips may be fastened together using heat and/or pressure applications. Additionally, the method for the production of the core member is provided.

A hierarchical sandwich core in the form of a honeycomb, i.e. having repetitive and periodic lattice materials. The sandwich core can be made up of a macroscopic honeycomb structure with sandwich cell walls having a mesoscopic cellular core. The longitudinal axis of cells of the mesoscopic honeycomb cell can be perpendicular to the longitudinal axis of the cells of the macroscopic honeycomb structure. Alternatively, if a foam core is used having mesoscopic cells the shape of the mesoscopic cells can be made during the foaming process so that they are elongate in a direction perpendicular to the longitudinal axis of the cells of the macroscopic honeycomb structure.