The present invention describes various methods for manufacturing gel composite sheets using segmented fiber or foam reinforcements and gel precursors. Additionally, rigid panels manufactured from the resulting gel composites are also described. The gel composites are relatively flexible enough to be wound and when unwound, can be stretched flat and made into rigid panels using adhesives.

Multifunctional surfacing materials for use in composite structures are disclosed. According to one embodiment, the surfacing material includes (a) a stiffening layer, (b) a curable resin layer, (c) a conductive layer, and (d) a nonwoven layer, wherein the stiffening layer (a) and the nonwoven layer (d) are outermost layers, and the exposed surfaces of the outermost layers are substantially tack-free at room temperature (20° C. to 25° C.). The conductive layer may be interposed between the curable resin layer and the stiffening layer or embedded in the curable resin layer. According to another embodiment, the surfacing material includes a fluid barrier film between two curable resin layers. The surfacing materials may be in the form of a continuous or elongated tape that is suitable for automated placement.

A structural panel includes a first skin, a second skin and a core. The core is connected to the first skin and the second skin. The core includes a corrugated sheet of wire mesh that includes a plurality of corrugations. Each of the corrugations extends vertically between and engages the first skin and the second skin.

A composite material having at least two layers of reinforcing fibers impregnated with a curable resin; an interlaminar region formed between adjacent layers of reinforcing fibers; and a combination of polymeric toughening particles and fire-retardant particles in the interlaminar region.

A floor panel including at least one substrate and a top layer, where the substrate includes at least one first layer of a first thermoplastic material and a second layer of a second thermoplastic material. The second layer is adjacent to a first side of the first layer and the second layer provides the floor panel with its underside. The first layer is characterized by a first colour with saturation value S1 in the HSL colour space and the second layer is characterized by a second colour with saturation value S2 in the HSL colour space, where S1 is less than S2.

Provided is a joined body comprising a first joined member, a second joined member, and a joining layer that joins the first joined member and the second joined member, wherein the first joined member and the second joined member are each independently one selected from the group consisting of a metal member, a polyamide resin member, and a polyolefin resin member, and the joining layer is a layer formed of a resin composition having a co-continuous phase including a continuous phase A farmed of the polyamide resin and a continuous phase B formed of the polyolefin resin and has a dispersed domain a distributed in the continuous phase A, a finely dispersed subdomain a′ distributed in the dispersed domain a, a dispersed domain b distributed in the continuous phase B, and a finely dispersed subdomain b′ distributed in the dispersed domain b.

A composite roof panel of a vehicle disposed vertically above a passenger cabin of the vehicle includes: a first one or more layers of carbon fiber; a second one or more layers of carbon fiber; a binder material configured to bind the first and second one or more layers of carbon fiber; first and second electrical conductors that are: disposed between the first one or more layers of carbon fiber and the second one or more layers of carbon fiber; configured to be selectively electrically connected to a battery of the vehicle; and electrically connected to at least one of the first and second one or more layers of carbon fiber.

Embodiments are directed to systems and methods for two or more cured composite assemblies that are bonded together to form a tubular composite structure, wherein each of the cured composite assemblies do not have a tubular shape. The tubular composite structure may form a spar for an aerodynamic component, for example. The two or more cured composite assemblies may comprise carbon or fiberglass composite materials or a combination of materials. Each of the cured composite assemblies may further comprise axial edges that are configured to be bonded to another of the cured composite assemblies, wherein the axial edges have a sloped shape. An adhesive agent may be applied on the axial edges for bonding two cured composite assemblies. Alternatively, or additionally, one or more fasteners may be used to attach the axial edges of at least two cured composite assemblies.

Apparatus and associated methods relate to using an additive (material deposition) process to incrementally form a closed-cell lattice structure formed as a unitary body in the shape of a marine hull cavity, the unit cells of the closed-cell lattice structure are substantially hollow. In an illustrative example, a method may include (a) forming a closed-cell lattice structure through additive manufacture, the hull cavity material may be bonded to an upper manufactured liner and a lower manufactured liner through lamination or mechanical connection. Unit cells of the closed-cell lattice structure may include hollow voids filled with gases. Providing the additive manufactured closed-cell lattice structure with a unitary body and hollow voids to trap gases may further advantageously promote the buoyancy and reduce the degeneration of a marine hull.

A laminated panel is provided comprising a skeletal framework, foam core inserts, an impact resistant sheet, and a weather resistant sheet bonded together with adhesive. Recreational vehicles incorporating such panels are also contemplated, as are methods of making the composite laminated panel.