A honeycomb extrusion die (120) includes a die body (302) including an inlet face (306) and an exit face. The die body (302) has slot inlets (309) and a plurality of pins (320, 500) disposed between the slot inlets (309) and the exit face. The plurality of pins (320, 500) include side surfaces (322, 500B) configured to define a matrix of intersecting slots (324), wherein the matrix of intersecting slots (324) has slot exit (509) widths at the exit face. Divots (526) extend into a plurality of the side surfaces (322, 500B) between the slot inlets (309) and the exit face. Each individual divot (526) has a divot depth (D55) extending into a side surface (500A, 500B, 502A, 502B) of the side surfaces (322, 500B). A ratio between a slot exit width (W53) W53 of an individual slot (324) and the divot depth (D55) of an individual divot (526) extending into a side surface (500A, 500B, 502A, 502B) of the individual slot (324) is greater than 1.2. Methods of forming honeycomb bodies with honeycomb structures are provided, as are other aspects.

A method of repairing a sandwich structure includes: removing a damaged portion of a core and a damaged portion of a first facesheet to form an open volume; filling the open volume with an ultraviolet-curable photomonomer; partially curing the ultraviolet-curable photomonomer to form a plurality of photopolymer waveguides by utilizing ultraviolet light; and arranging a replacement facesheet on the damaged portion of the first facesheet and over the photopolymer waveguides.

Disclosed herein is a molded laminated structure having negative draft angles and methods of manufacturing a molded laminated structure having negative draft angles. A preliminary structure having a first outer layer and a second outer layer is molded with a bend that divides the preliminary structure into two sections with an angle between the two sections of less than 180-degrees. Portions that extends from the sections are at positive draft angles. A groove is formed in the preliminary structure at the bend but not formed in a constant cross-section of the second outer layer. The preliminary structure is folding along the bend to at least partially close the groove and form a molded laminated structure with portions that extend at a negative draft configuration while retaining the second outer layer continuous throughout the molded laminated structure.

A composite sandwich panel comprises a first composite skin, a second composite skin, a hollow cell core between the first composite skin and the second composite skin, and a first over-crush edge region with a first edge. The first edge has a first thickness at least 40% less than a nominal thickness of the composite sandwich panel. The first over-crush edge region has a length of at least 0.25 inches over which a thickness of the composite sandwich panel decreases.

A method for producing a honeycomb structure according to the present invention includes: a preparation step of preparing a honeycomb structure element 2 having plurality of slits 12; and a filling step of filling the plurality of slits 12 with a filling material 13 by a contacting member 3 by feeding the filling material 13 to an outer peripheral surface 20 of the honeycomb structure element 2, and rotating the honeycomb structure element 2 while pressing a tip portion 3a of the contacting member 3 inclined at an angle relative to a normal line 20a of the outer peripheral surface 20 of the honeycomb structure element 2 against the outer peripheral surface 20 with a force, to obtain the honeycomb structure having the plurality of slits 12 filled with the filling material 13.

A method of making an article is provided, including placing at least a portion of a panel in an injection molding die and overmolding at least one molded structure on a surface of the panel in the injection molding die, wherein the molded structure includes a foam composition. An article is also provided including a material-to-material connection between the surface of a panel and a molded structure. The panel includes first and second layers and a core disposed there between, wherein the core has a plurality of walls providing a series of connected cells. Some of the cell walls have openings providing fluid communication between a series of at least 3 cells, and the opening in a cell wall has an area that is at least 50 percent of the area of a side of that cell wall. Articles such as panels, walls, or other parts with curved surfaces can be formed according to certain exemplary embodiments. The articles are useful for absorbing sound in a designed frequency range.

A system and a method for securing a first composite panel to a second composite panel include a latch assembly having one or more latches. The latch assembly is configured to be secured to one of the first composite panel or the second composite panel. One or more strikes are configured to retain at least a portion of the one or more latches. The one or more strikes are configured to be secured to the other of the first composite panel or the second composite panel.

Certain configurations of multilayer assemblies are described. In certain embodiments, the multilayer assembly can include a core layer, a skin layer and one or more depressions in a surface of the multilayer assembly. In other configurations, the multilayer assembly can include a core layer, a skin layer, one or more depressions in a surface of the multilayer assembly and one or more additional layers.

An extrusion die (100) for a honeycomb body, the die (100) including: an input surface (102); an opposing output surface (104); feed holes (108) extending from the input surface (102) toward the output surface (104); discharge slots (106) having a slot width (SW) and a slot length (SL), and extending from the output surface (104) toward the input surface (102); and a plenum (130) fluidly connecting the feed holes (108) and the discharge slots (106). The plenum (130) may include chambers (132) connected to the feed holes (108) and including tapered outlets (134) connected to the discharge slots (106). The plenum (133) may include first chambers (132A) connected to the feed holes (108) and including first tapered outlets (134A), and second chambers (132B) connected to the first outlets and including second tapered outlets (134B) connected to the discharge slots (106).

A process for producing a sandwich component. A first covering layer is formed on a molding surface of a molding tool; a core is produced by building up a cell structure having a multiplicity of cells in a thickness direction on the first covering layer via an additive production process; and a second covering layer is formed on a deposition surface of the core, the surface being situated on the opposite side from the first covering layer. A core for a sandwich component is furthermore described, as is a sandwich component.