A method for the production of an FMV hybrid component includes braiding a dry hybrid fibre thread onto a core element, where a hybrid fibre braid is formed, and obtaining a fibre core composite. The method further includes reshaping the fibre core composite and impregnating and consolidating the hybrid fibre braid on the core element.

A method of manufacturing a composite component comprises forming a core, surrounding the circumference of the core with a first layer of fabric, applying a second layer of fabric having a different coefficient of thermal expansion from the first layer such that the second layer extends around at least a portion of the circumference of the core and curing the component such that the second layer imparts a compressive or tensile force on the core.

Co-molding of non-crimped fabric and sheet molding composition. The pre-preg of non-crimped fabric is dried to achieve suitable stiffness for molding. The pre-preg allows the pre-formed non-crimped fabric feature to retain its shape during molding. A plurality of thorns is provided in the molding tooling to further prevent movement of pre-preg during molding. The method of co-molding includes, drying of the pre-preg to achieve suitable stiffness for molding, pre-forming of the pre-preg, and incorporating a plurality of stand-off features or thorns in the molding tool to prevent movement of pre-preg during co-molding so that predetermined full coverage of non-crimped fabric is maintained in predetermined area(s) of the molded part and the continuous fibers of the non-crimped fabric are not distorted.

A composite core material and methods for making same are disclosed herein. The composite core material comprises mineral filler discontinuous portions disposed in a continuous encapsulating resin. Further, the method for forming a composite core material comprises the steps of forming a mixture comprising mineral filler, an encapsulating prepolymer, and a polymerization catalyst; disposing the mixture onto a moving belt; and polymerizing said encapsulating prepolymer to form a composite core material comprising mineral filler discontinuous portions disposed in a continuous encapsulating resin.

The present invention addresses the problem of providing a composite material that can prevent a strength reduction when fibers of a skin material are bent during curing of the composite material. In a composite material, a filler is arranged between a honeycomb core and a first skin material and/or between the honeycomb core and a second skin material so as to overlap the tip of an end of the honeycomb core. In a horizontal view, the filler arranged between the honeycomb core and the second skin material protrudes outside the composite material by a length equal to or less than a length of a portion thereof overlapping the tip of the end of the honeycomb core.

A shaped preform component (200) for a face portion (104) of a composite wheel (100), the shaped preform (200) having a hub (206) that extends around a central axis (Y), the shaped preform component (200) being formed from a cured composite fibre material having a compressibility of <2% volumetric under moulding conditions of 50 bar hydrostatic pressure and a temperature of 60 to 200 C.

A shaped preform component (200A) for a spoke portion (108A) of a composite wheel (100), the shaped preform (200A) comprising: an elongate body (215) configured to be located in a spoke (108) of a composite wheel (100), wherein the shaped preform component (200A) is formed from a cured composite fibre material having a compressibility of <2% volumetric under moulding conditions of 50 bar hydrostatic pressure and a temperature of 60 to 150 C., and wherein the density of the cured composite fibre material is selected to form a counterbalance mass for a mass addition (300) to the composite wheel (100).

Provided is a technique for forming a honeycomb sandwich composite material which is easy and can be automated. The honeycomb sandwich composite material 30 comprises a honeycomb core 20, an FRP lower portion, and an FRP upper portion. A first prepreg sheet laminate 21 serves as the FRP upper portion. A second prepreg sheet laminate 22 serves as the FRP lower portion. A jig 10 having a concave 11 corresponding to the upside-down shape of the honeycomb 20 is used in the shaping step and the curing step. The laminate 21 is shaped so as to correspond to the concave 11 by a hot drape device (S15), the honeycomb core is disposed upside-down (S16), and the laminate 22 is placed thereon (S17). Without removing the mold, curing is effected by an autoclave device, the mold is removed after curing, and the composite material is turned upside-down.

A process for the production of composite materials at low temperatures, as well as a composite material obtained by the process and articles of manufacture comprising the composite material are provided.

A cover for a cushion includes a first panel, a second panel, and a primary receptacle defined between the first panel and the second panel. The primary receptacle may receive a primary cushioning element, such as a pillow, a pillow insert, or a fill material. At least one of the first panel and the second panel includes a secondary cushioning element. The secondary cushioning element may be defined from a compressible, resilient elastomeric material that defines a plurality of thin interconnected walls that in turn define an array of open cells or columns. Each cell or column may have a hexagonal shape, imparting the array of open cells or columns with a honeycomb appearance. Methods for assembling a primary cushioning element with such a cover are also disclosed.