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.

A method for forming composite materials and associated apparatuses is presented, including positioning at least one electronic component on a lay-up surface. The method also includes positioning a composite on the lay-up surface, where the composite comprises resin and fibers. Additionally, the method includes causing a flow of the resin between the lay-up surface and the fibers. Yet further, the method includes curing the resin to form a cured resin, where the electronic component and the fibers are located in the cured resin. The composite material includes a resin having a shape based on a surface of a lay-up system. Additionally, the composite material includes fibers contained within the resin. Further, the composite materials includes at least one electronic component. The electronic component of the composite material is located in the resin based on a flow of the resin around the electronic component on the surface of the lay-up.

The present disclosure provides an apparatus that includes a fiber gun. In an embodiment, the apparatus may controllably cut one or more fibers into one or more fiber segments. In an embodiment, the apparatus may controllably shape one or more fibers into different shapes (e.g., from loops into substantially straight fibers). In an embodiment, the apparatus may controllably position the one or more fiber segments onto a supporting member (e.g., a composite component). For example, the apparatus may include a robot that may controllably move the fiber gun relative to a supporting member and align the fiber gun such that the one or more fiber segments are controllably positioned on the supporting member. The apparatus may further include a controller that at least partially controls operation of the apparatus.

Sound-attenuating mufflers and muffler inserts, and systems and methods for fabricating such muffler inserts. Continuous fiberglass roving is fed to a pneumatic jet head which fluffs the roving and presents the fluffed roving to a delivery wand at the exit end of the jet head. A jet head/wand assembly is moved along a three-dimensional path such that the wand delivery tip travels along a predetermined three-dimensional path inside a mold thereby depositing the continuous, fluffed fiberglass strands in the mold along the predetermined path. A terminal end portion of a liquid resin conduit is mounted to the fiberglass-dispensing wand, as part of the delivery tip, and drip-feeds liquid resin onto the fiberglass as the fiberglass is being deposited in the mold. The undulating, up and down movement of the delivery tip produces a wave-like undulating pattern in the appearance of the rovings in the resulting molded product.

A device and method for applying a reactive mixture comprised of at least two components to a substrate (41) having a spraying device (10) capable of generating a planar, fan-shaped spray jet (18) and a round spray jet (17), and having a means for moving the spraying device relative to the substrate, wherein the spraying device is moved over the substrate in at least two stages, wherein in the first stage, a first application of material (42) is performed with reactive mixture, using the planar, fan-shaped spray jet, on the substrate, and in a further stage a second application of material (43a-c) is subsequently performed with reactive mixture, using the round spray jet, on at least a section of the material applied to the substrate in the first application of material.

The present disclosure provides a composite tube and a method for producing a composite tube for a vehicle body. The method includes the steps of: providing a metal tube; forming the tube into a prespecified shape; introducing a spray gun into the tube; and spraying on a fiber coating in at least one region of the inner side of the tube using the spray gun. The fiber coating is a matrix material with embedded fibers. The method further includes removing the spray gun from the tube, and hardening the fiber coating. The present disclosure also provides a motor vehicle having a vehicle body which includes a composite tube.

An aircraft panel assembly with a panel and a plurality of stiffeners on the panel is disclosed. Each stiffener has an attachment part attached to the panel and a structural part spaced apart from the panel. A rib foot beam crosses the stiffeners at a series of intersections. At each intersection the rib foot beam is located between the panel and the structural part of a respective one of the stiffeners.

A composite core structure includes a core having a plurality of elongated fibers and a plurality of spherical members, the elongated fibers and spherical members consolidated into a desired molded shape. The composite core structure also includes a matrix material encapsulating the elongated fibers and spherical members.

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 apparatus (1) for making a fibrous-containing and/or particle-containing nonwoven (NW) comprises a spinning unit (10) with a spinning head (104), a forming surface (11a) that is movable in a conveying direction (MD), and a channel (13) positioned between the spinning head (104) and the movable forming surface (11a), and formed between at least two transverse walls (14a; 14b), that extend transverse to the conveying direction (MD) and that are in the vicinity of the movable forming surface (11a), or that are in frictional contact with the movable forming surface (11a). The spinning unit (10) is adapted for spinning a stream of polymeric filaments or fibres (F) passing through said channel (13) and deposited onto said forming surface (11a). The apparatus further comprises supplying means (15) adapted for blowing at least one stream of cooling gas (C) and fibrous material and/or particles inside said channel (13) in the vicinity of the spinning head (104) and towards the stream of hot polymeric filaments or fibres (F) inside said channel (13), said at least one stream of cooling gas (C) enabling simultaneously to cool the stream of hot fibres or filaments (F) produced by the spinning unit (10) and to transport and blow the fibrous material (M) and/or particles inside said channel (13) and into said stream of hot polymeric filaments or fibres (F).