Cushioning articles or structures are provided including a cell layer with an array of cells interconnected with each other. Each of the cells includes at least three cell walls extending between the first and second major surfaces thereof. The cell walls are shared by the adjacent cells, and the cell layer further includes a land region located at the second major surface and connecting the at least three cell walls. A base layer is attached to the second major surface of the cell layer to form a sheet.

Methods and apparatus for making and using tools, for example concrete cutting blades. The tool includes a first layer and a second layer that are oppositely disposed. The first and second layers include working surfaces that support at least one working element when the working element is applied to a work piece. Additionally, an intermediate structure is included between the first and second layers. The intermediate structure can include a plurality of components extending in the area between the structural surfaces and the working surfaces.

In a preferred embodiment, a composite panel with a smooth outer surface, ready for painting with or without addition of primer, may be created by constructing a panel layup assembly upon a mold, the panel layup assembly including a composite panel having a core and a resin formulation, and a release film between the mold and the composite panel, where a smooth release surface of the release film is in contact with the composite panel upon construction; initiating curing of the composite panel at a first temperature within a lowermost ten percent of a curing temperature range of the resin formulation; continuing curing of the composite panel at a second temperature above the lowermost ten percent of the curing temperature range; and completing curing of the composite panel at a third temperature below the second temperature.

A motor vehicle roof shell having a rigid composite component having an inner side facing a vehicle interior, and an acoustic insulation layer disposed on the inner side of the composite component. The panel-type rigid composite component has at least one tray-like recess on its inner side, said recess being filled with an open-pored foam material which forms the acoustic insulation layer and whose surface is flush with a surface of the composite component surrounding the recess. A motor vehicle roof shell motor vehicle having a panel-type rigid composite component having an inner side, which faces the vehicle interior, and an acoustic insulation layer disposed on the inner side of the composite component, wherein the acoustic insulation layer is formed by at least one rigid-foam or semi-rigid-foam plate which is bonded to the inner side of the composite component and compressed that its volume is reduced compared to preassembly state.

A marine deck member with enhanced surface traction and the process for forming the same. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold-pressing in a mold. The cellular core has a 2-D array of cells, each of the cells having an axis substantially perpendicular to the outer surfaces, and extending in the space between the layers or skins, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be effected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold. The embossing can be effected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.

A method and apparatus for forming a ribbon configured for use in forming a honeycomb structure when the ribbon is in a folded state. The ribbon comprises a first edge and a second edge. At least one portion of the first edge is not parallel to at least one portion of the second edge when the ribbon is in an unfolded state.

A honeycomb for curved surface lightweight components includes a plurality of elongate ribbons and connecting regions. The connecting regions are provided, respectively, between opposing ribbons to connect the ribbons together in a portion-wise manner in a firmly bonded relationship in a transverse direction. The connecting regions are arranged at regular spacings along the longitudinal direction of a ribbon. Honeycomb-like cells form cavities between the ribbons. With respect to three successive ribbons, a displacement of the connecting regions between first and second ribbons relative to the connecting regions between second and third ribbons toward a first side of the longitudinal direction is lesser than toward a second side of the longitudinal direction. Consequently, at least a part of the cells in cross-section in the longitudinal direction/transverse direction plane have at least one longer limb corresponding to the greater displacement and at least one shorter limb corresponding to the lesser displacement.

A composite ballistic panel provides cost-effective ballistic protection against projectiles. The composite ballistic panel comprises a composite ballistic assembly with an impact/strip layer that alters the projectile during striking contact with the projectile by flattening the projectile, distorting the shape of the projectile, reducing rotation of the projectile, reducing the velocity of the projectile, and inducing yaw to the projectile; a non-ballistic deflection layer that forms a cavity to inhibit propagation of the projectile's shock wave; and a containment layer that stops and captures the projectile within the composite ballistic assembly. Additionally, the composite ballistic panel may have a protection layer and a boundary edge to enhance capture of the projectile and ballistic characteristics, and an intermediate layer that acts as spacer between layers.

Methods for reworking structures and reworked cellular core panels, reworked structures comprising the reworked cellular core panels, and guides and cutting apparatuses for reworking cellular acoustic panels and reworking cellular acoustic and non-acoustic panels are disclosed.

In a preferred embodiment, a composite panel with a smooth outer surface, ready for painting with or without addition of primer, may be created by constructing a panel layup assembly upon a mold, the panel layup assembly including a composite panel having a core and a resin formulation, and a release film between the mold and the composite panel, where a smooth release surface of the release film is in contact with the composite panel upon construction; initiating curing of the composite panel at a first temperature within a lowermost ten percent of a curing temperature range of the resin formulation; continuing curing of the composite panel at a second temperature above the lowermost ten percent of the curing temperature range; and completing curing of the composite panel at a third temperature below the second temperature.