Systems and methods for improving adhesion of an insulating foam to a molded polymeric insulating structure through use of ozone gas for functionalization of molded polymeric surfaces of an internal cavity of the insulating structure.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

Nozzles are presented, for application of a setting resin into cells of a honeycomb core to provide the panel with reinforced segments. The nozzle comprises a connector portion and an application head, where the connector portion is adapted to receive setting resin from a resin dispensing device and deliver the setting resin to the application head, and the application head comprises: an exit hole, and a flange surrounding the exit hole. The flange comprises a bottom surface which comprises a planar surface which planar surface has a minimum width around the exit hole. The bottom surface of flange curves upward at its outer perimeter. In some embodiments, the nozzle is optically translucent or transparent. In addition, methods of applying a setting resin into cells of a honeycomb core to form a honeycomb core reinforcement are presented. In some embodiments, the setting resin is a low density void filler.

A structural component for a vehicle and a process and system for forming the structural component. A first cavity is formed in a first hollow passage between a first bladder and an interior surface of a component forming the structural component. A first structural reinforcement layer is formed in the first cavity by filling the first cavity with a first polymer resin and foaming the first polymer resin to form a first polymer resin foam. A second cavity is formed in the first hollow passage and a second structural reinforcement layer is formed in the second cavity by filling the second cavity with a second polymer resin and foaming the second polymer resin to form a second polymer resin foam.

A method of manufacturing a custom elastomeric earmold with a secondary material infusion and said custom elastomeric earmold is disclosed. The method can include establishing a representation of a shape of the ear concha, the outer canal and the inner ear canal cavity. The method may further include casting a custom shaped injection mold. The injection mold may be used to cast a custom shape of the inner and outer ear from an elastomeric material such as silicone or urethane. An additional injection step can be performed to infuse foam into the interior of the elastomeric material.

A panel structure and a method of forming the panel structure are disclosed. The panel structure typically includes at least one panel associated with a material. The panel structure has been found particularly advantageous for use as an interior panel of an airplane.

Systems and methods for improving adhesion of an insulating foam to a molded polymeric insulating structure through use of ozone gas for functionalization of molded polymeric surfaces of an internal cavity of the insulating structure.

Systems and methods for improving adhesion of an insulating foam to a molded polymeric insulating structure through use of ozone gas for functionalization of molded polymeric surfaces of an internal cavity of the insulating structure.

A panel structure and a method of forming the panel structure are disclosed. The panel structure typically includes at least one panel associated with a material. The panel structure has been found particularly advantageous for use as an interior panel of an airplane.

A pad is provided for supporting heavy loads and is capable of supporting loads of 100 tons or more. The pad has a core having a bi-directional grid formed from parallel fiberglass materials, with a first set of material at right angle to a second set of fiberglass materials and which grid surrounds a closed cell material, which is infused with resin to form a core. A fiberglass top surface, bottom surface and at least one sidewall is provided. The result is a pad able to distribute very heavy loads, is resistant to bending, durable and light weight.