A method of making an aircraft acoustic structural panel (10) begins with preforming a core honeycomb laminate (12) having preformed foam (3) bonded inside cells (14) thereof by a distinct adhesive (2). The preformed honeycomb laminate (12) is then stacked between opposite top and bottom structural outer laminates (16,18). The stacked honeycomb laminate (12) and outer structural laminates (16,18) are then compressed together under heat and pressure into a unitary structural panel (10) having the core honeycomb laminate (12) integrally bonded between outer skins (20,22). The outer laminates (16,18) may include imperforate acoustic septums (4) bounding the core honeycomb laminate (12) followed by an outer honeycomb (5) and structural fiber layers (6,7,8) defining the outer skins (20,22).

Adhesive bondlines in a cell-based structural array are thermally cured using tooling blocks inserted into the cells. The tooling blocks have embedded susceptors that are inductively heated by an alternating electromagnetic field generated by an electromagnet.

A composite sandwich panel assembly including an open area core, a high gloss surface sheet, and a structural skin. The open are core defines a plurality of pores and has a first face and an opposing second face. The high gloss surface sheet is adhered to the first face of the open area core by a first adhesive layer. The high gloss surface sheet has a high gloss surface. The structural skin is adhered to the second face of the open area core by a second adhesive layer. A process for forming the composite sandwich panel assembly includes positioning the high gloss surface sheet, joining the first face of the open area core to the high gloss surface sheet with a first adhesive layer intermediate therebetween, and joining the structural skin to the second face of the open area core with a second adhesive layer intermediate therebetween.

A method of making an aircraft acoustic structural panel (10) begins with preforming a core honeycomb laminate (12) having preformed foam (3) bonded inside cells (14) thereof by a distinct adhesive (2). The preformed honeycomb laminate (12) is then stacked between opposite top and bottom structural outer laminates (16,18). The stacked honeycomb laminate (12) and outer structural laminates (16,18) are then compressed together under heat and pressure into a unitary structural panel (10) having the core honeycomb laminate (12) integrally bonded between outer skins (20,22). The outer laminates (16,18) may include imperforate acoustic septums (4) bounding the core honeycomb laminate (12) followed by an outer honeycomb (5) and structural fiber layers (6,7,8) defining the outer skins (20,22).

An acoustic liner and a method of attenuating noise are provided. The acoustic liner includes a face sheet, a back sheet spaced from the face sheet, and a core layer extending between the face sheet and the back sheet. The core layer includes a plurality of resonant cells, each resonant cell including at least one cell wall coupled to the back sheet along a cell wall base edge. The at least one cell wall extends from the back sheet at an angle toward the face sheet. The at least one cell wall further coupled to the face sheet along a cell wall top edge. The resonant cell is formed in a predetermined shape and contains a volume in a space defined by the at least one cell wall, the back sheet, and the face sheet. The cell wall base edge length is greater than the cell wall top edge length.

An impact attenuation system comprises an aluminum honeycomb sheet having a top surface and a bottom surface. The aluminum honeycomb sheet defines a plurality of approximately hexagonally shaped cells. The bottom surface defines a single sheet of contiguous cells and the top surface defines two or more islands of contiguous cells separated by one or more slits. At least a portion of one or both of the top surface and bottom surface may be covered by a polymer skin. The polymer skin may comprise carbon fibers and/or fiberglass.

Embodiments disclosed herein relate to composite laminate structures including a polymer layer having sp.sup.2 carbon-containing material and improved heat release properties, and methods of making the same.

The present disclosure discloses an ultrasonic cutting holder for a honeycomb core, including a holder, a swing mechanism, a transducer, a first-stage amplitude transformer, a second-stage amplitude transformer, an ultrasonic cutting tool, and an ultrasonic power transmission mechanism. The present disclosure provides an ultrasonic cutting holder for a honeycomb core with large amplitude output capacity and considering the interchangeability requirements among different vibration systems, which solves the problem of the applicability of ultrasonic cutting holder on the universal machine tool and improves the automation level of ultrasonic cutting.

A low cost and disaster relief housing solution includes the combination of preconstructed in-service or out-of-service shipping containers that are integrated with renewable and sustainable materials to complete the buildout of the shipping containers. The embodiment also includes folding solutions that allows for a superior logistic solution for shipping and site integration.

In accordance with one embodiment of the present disclosure, a method for manufacturing a honeycomb core sandwich panel includes placing a thermoset facesheet in contact with a thermoplastic honeycomb core without using a separate adhesive and attaching the thermoset facesheet to the thermoplastic honeycomb core by using a curing profile comprising a temperature that is lower than a gel point temperature of the thermoset facesheet and higher than a softening point temperature of the thermoplastic honeycomb core.