Methods and apparatus to remove gas and vapor from a panel for a decorative layer are disclosed. An example apparatus includes a first press plate of a hot press to engage a first surface of a panel. The hot press is to apply heat to the panel via the first press plate to cure resin of the panel. A first portion of the first press plate is composed of a permeable material to remove at least one of gas or vapor from the panel to deter the at least one of gas or vapor from exerting a pressure on a decorative layer to be coupled to the panel to deter separation of a portion of the decorative layer from the panel.

Methods and apparatus to couple a decorative layer to a core layer of a panel via a barrier layer are disclosed. An example apparatus includes a decorative layer coupled to a panel. The panel has a core layer. The example apparatus includes a barrier layer disposed between the core layer and the decorative layer. The barrier layer is to impede at least one of gas or vapor from escaping from the core layer to the decorative layer to deter the at least one of gas or vapor from exerting a pressure on the decorative layer to deter a portion of the decorative layer from separating from the panel.

Methods and apparatus to couple a decorative layer to a panel via a high-bond adhesive layer are disclosed. An example apparatus includes a panel, a high-bond adhesive layer fixed to the panel, a liner fixed to the high-bond adhesive layer that is fixed to the panel, and a first decorative layer removably coupled to the liner that is fixed to the high-bond adhesive layer via a second adhesive layer. The high-bond adhesive layer is to impede at least one of gas or vapor from escaping the panel to deter the at least one of gas or vapor from exerting a pressure on the first decorative layer to deter a portion of the first decorative layer from separating from the panel.

Methods and apparatus to form venting channels on a panel for a decorative layer are disclosed. An example method includes contacting an outer surface of a tool to an outer resin layer of a panel. The outer surface of the tool has protrusions. The example method includes moving the outer surface of the tool on the outer resin layer of the panel in a first direction to cause the protrusions of the tool to form first venting channels on the outer resin layer of the panel and coupling a decorative layer to the outer resin layer of the panel via an adhesive layer. The first venting channels are to vent at least one of gas or vapor away from the decorative layer to deter separation of a portion of the decorative layer from the outer resin layer.

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.

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.

The disclosure relates to additively manufactured (AM) composite structures such as panels for use in transport structures or other mechanized assemblies. An AM core may be optimized for an intended application of a panel. In various embodiments, one or more values such as strength, stiffness, density, energy absorption, ductility, etc. may be optimized in a single AM core to vary across the AM core in one or more directions for supporting expected load conditions. In an embodiment, the expected load conditions may include forces applied to the AM core or corresponding panel from different directions in up to three dimensions. Where the structure is a panel, face sheets may be affixed to respective sides of the core. The AM core may be a custom honeycomb structure. In other embodiments, the face sheets may have custom 3-D profiles formed traditionally or through additive manufacturing to enable structural panels with complex profiles. The AM core may include a protrusion to provide fixturing features to enable external connections. In other embodiments, inserts, fasteners, or internal channels may be co-printed with the core. In still other embodiments, the AM core may be used in a composite structure such as, for example a rotor blade or a vehicle component.

A method, apparatus, and system for reticulating an adhesive on a workpiece. The workpiece may be perforated with a plurality of passages that extend through a first side to a second side. To reticulate an adhesive on the first side of a workpiece, a flow of heated fluid is provided through a nozzle. The nozzle provides the fluid at a first pressure to a first group of the perforations. Once the temperature at the first side of the workpiece reaches a specified range, the fluid pressure may be increased or otherwise set in order to clear the perforations by forcing the adhesive out of or away from each of the perforations. Temperature of the adhesive, pressure within the nozzle, and/or light passage through the perforations may be monitored for logical control or quality assurance.

A honeycomb structural body includes multiple cores, at least face sheet, and at least one reinforcement sheet. The multiple cores each have a honeycomb structure, and are bonded to each other with foamed adhesive in a direction in which the number of multiple pores formed by the honeycomb structure increases. The at least one face sheet is adhered to the multiple cores so as to cover the multiple pores. The reinforcement sheet is placed between the multiple cores and the at least one face sheet, at a position where the reinforcement sheet covers the foamed adhesive.

A method and apparatus for forming a sandwich structure is presented. A sandwich structure comprises a metallic core layer and a thermoplastic layer on a first side of the metallic core layer. The thermoplastic layer is consolidated against the first side of the metallic core layer.