A system and method for producing a board product characterized by having two corrugated mediums and at least one embossed medium in the board product. The board product may further include one or more facings that are adhesively coupled to either the corrugated medium, the embossed medium, or both. Generally speaking, a corrugated medium may be characterized as a paper product that exhibits flutes induced by a cross-corrugating process such that the induced flutes are perpendicular (or at least not congruent) with the machine direction of the paper product. An embossed medium may be characterized as a paper product that exhibits flutes induced by a linear-embossing process such that the induced flutes are aligned with the machine direction of the paper product. A resultant board product is stronger and more efficiently produced because of the linearly-embossed medium harnessing the natural strength of the paper in the machine direction.

A device and production method, in which a workpiece is built up gradually in layers. To build up the workpiece, preformed layers, which are individually formed on a layer support using an electrophotographic printing process are transferred one at a time from the layer support to the workpiece. For this purpose, the layer is transferred to the workpiece in a printing operation, the layer being preferably laid on the workpiece by a die. In one embodiment, a plurality of workpieces are built up simultaneously and a plurality of preformed layers are transferred simultaneously to different respective workpieces. In another embodiment, the layer is formed on the layer support, which is preferably a film or paper, prior to being transferred.

A system and method for producing a board product characterized by having two corrugated mediums and at least one embossed medium in the board product. The board product may further include one or more facings that are adhesively coupled to either the corrugated medium, the embossed medium, or both. Generally speaking, a corrugated medium may be characterized as a paper product that exhibits flutes induced by a cross-corrugating process such that the induced flutes are perpendicular (or at least not congruent) with the machine direction of the paper product. An embossed medium may be characterized as a paper product that exhibits flutes induced by a linear-embossing process such that the induced flutes are aligned with the machine direction of the paper product. A resultant board product is stronger and more efficiently produced because of the linearly-embossed medium harnessing the natural strength of the paper in the machine direction.

A method of manufacturing a composite fan blade with an outer part and a core includes laying up a plurality of continuous plies to achieve a stack, placing the core on a central portion of the stack of continuous plies to achieve an unfolded preform; folding the contin-uous plies about the core, such that the central portion of the stack folds about the core and the first portion is superimposed to the second portion, to achieve a folded preform; apply-ing pressure to the folded preform to achieve a consolidated curved folded preform; curing the consolidated curved folded preform to achieve the composite fan blade.

Systems and methods for filament fastener that cures with composite part. One embodiment is a method of fabricating a composite part. The method includes placing layers of reinforcement fibers over a tool to form a laminate of composite material to be cured with a first resin, forming a filament fastener comprising bundled fibers with one or more texture elements around the bundled fibers, and coating the filament fastener with a second resin that is chemically compatible with the first resin. The method also includes inserting the filament fastener into the laminate through a plurality of the layers, and curing the filament fastener within the laminate to bind the plurality of the layers of the laminate with the one or more texture elements of the filament fastener via bonding of the first resin and the second resin to form the composite part with delamination resistance.

Sheets of a thin film material are attached to a carrier wafer. The carrier wafer and the attached sheets of thin film material are separated to form chiplet carriers. Each chiplet carrier includes a portion of the sheets of thin film material attached to a portion of the carrier wafer. The chiplet carriers are placed on an assembly surface in a random pattern. The chiplet carriers are arranged from the random pattern to a predetermined pattern, and the portions of the thin film material are transferred from the chiplet carriers to a target substrate.

Embodiments are directed to systems and methods for creating a tubular composite structure. In one embodiment, a device comprises multiple layers of cured composite fabric bonded together to form a tubular composite structure, wherein alternating groups of the multiple layers comprise on-axis fabric and off-axis fabric. The tubular composite structure may form a spar for an aerodynamic component. The composite fabric may comprise one or more of carbon, fiberglass, or other composite materials, or a combination of materials. One or more stacks of the fabric wrap completely around the tubular composite structure, and other stacks of fabric may not wrap completely around the tubular composite structure.

Systems and methods for filament fastener that cures with composite part. One embodiment is a method of fabricating a composite part. The method includes placing layers of reinforcement fibers over a tool to form a laminate of composite material to be cured with a first resin, forming a filament fastener comprising bundled fibers with one or more texture elements around the bundled fibers, and coating the filament fastener with a second resin that is chemically compatible with the first resin. The method also includes inserting the filament fastener into the laminate through a plurality of the layers, and curing the filament fastener within the laminate to bind the plurality of the layers of the laminate with the one or more texture elements of the filament fastener via bonding of the first resin and the second resin to form the composite part with delamination resistance.

The present invention provides a tool 1 for curing a composite component, the tool comprising a lay-up surface 8 for laying-up layers of an uncured composite component, a cover assembly 9 for moving in relation to the lay-up surface to cover a layed-up uncured composite component on the lay-up surface, the cover assembly comprising a sealable cover for sealing around the uncured composite component on the lay-up surface to form a sealed zone, and a vacuum port 25 for providing a vacuum to the sealed zone, wherein the tool further comprises at least one heating element 15, 53 within the sealed zone for heating the uncured composite component. The invention also provides a method of manufacturing a composite component and a composite component. The composite component may form at least part of a piece of aircraft furniture, such as an aircraft seat shell.

A fluid-filled chamber is provided and includes a first barrier layer, a second barrier layer, a foam structure, and a tensile member. The second barrier layer is secured to the first barrier layer to define an interior void between the first barrier layer and the second barrier layer. The interior void contains a predetermined volume of fluid. The foam structure and the tensile member are disposed within the interior void, whereby the tensile member includes a plurality of fibers extending in a first direction between the first barrier layer and the second barrier layer.