Methods for reworking structures and reworked cellular core panels, reworked structures comprising the reworked cellular core panels, and guides and cutting apparatuses for reworking cellular acoustic panels and reworking cellular non-acoustic panels are disclosed.

A method of anchoring a connector in a first object, wherein the first object is a lightweight building element having a first outer building layer and an interlining layer, and wherein the connector includes thermoplastic material in a solid state. The method includes: bringing a coupling surface portion of the connector into contact with an attachment location of the first outer building layer; displacing a portion of the first outer building layer at the attachment location with respect to the interlining layer by applying a first pressing force to the first outer building layer and thereby piercing the first outer building layer; applying a second pressing force to the connector and transferring energy to the connector until a flow portion of the thermoplastic material has liquefied and flown to interpenetrate structures of the interlining layer; and stopping the energy transfer and allowing the flow portion to re-solidify.

An automated fastener insert installation system for composite panels is provided. A first module receives and secures a composite panel with respect to an origin of a first coordinate system, wherein the composite panel has opposed major surfaces and defines an insert-receiving orifice extending through one of the major surfaces, and is secured such that one of the major surfaces is externally accessible. A second module engages each of a plurality of fastener inserts with an installation aide. Third module determines a configuration of the orifice defined by the composite panel, selects a corresponding one of the fastener inserts engaged with the installation aide, inserts the selected fastener insert into the orifice, and dispenses an adhesive material through the installation aide and into the orifice about selected fastener insert such that the adhesive material secures the selected fastener insert within the orifice. Associated systems are also provided.

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).

A method of fastening an edge structure to a construction element includes providing the construction element, being a planar structure with with two cover regions and a middle region between the cover regions; providing the edge structure being continuously extended, the edge structure having contact surfaces with a thermoplastic material shaped to lie against the cover regions in an outer surface of the construction element, and, opposite the contact surfaces, a coupling-in surface for coupling energy into the edge structure; coupling energy into the edge structure and pressing the contact surfaces against the cover regions until at least a portion of the thermoplastic material is liquefied and pressed into the cover regions; and repeating or continuing the steps of coupling and pressing until the edge structure is attached to the building element at a plurality of discrete locations or over an extended region along an edge of the construction element.

A method for joining a device to an object with the aid of a combination of ultrasonic vibration energy and induction heating, wherein the device includes a portion of a thermoplastic polymer and a susceptor additive wherein this portion is at least partly liquefied or plasticized through the ultrasonic vibration energy in combination with the induction heating and wherein the joining includes establishing a connection between the device and the object which connection is at least one of a positive fit connection, a weld, a press fit connection, and an adhesive connection. The induction heating is applied for rendering the device portion suitable for absorption of ultrasonic vibration energy than other device portions by raising its temperature above the glass transition temperature of the polymer. The ultrasonic vibration energy is used for liquefying or at least plasticizing the thermoplastic polymer of the named device portion.

A method and apparatus for fabricating a composite structure. The method comprises defining a shape for the composite structure with a first face sheet. The method places core sections on the shape defined by the first face sheet. The method places an adhesive in a group of joint cavities. The method places a second face sheet on the core sections placed on the first face sheet, wherein the first face sheet, the core sections, and the second face sheet, define a structural assembly in which the group of joint cavities are present. The method cures the structural assembly with the adhesive in the group of joint cavities to fabricate the composite structure in which the adhesive fills the group of joint cavities when the adhesive is cured.

A construction kit for a housing structure of a monument for a cabin of a vehicle, in particular of an aircraft includes a plurality of integrally formed sandwich panels which each have two cover panels, which surround a core, and are formed with panel connecting structures which are each formed as a plug region or as a mating plug region. The mating plug region is formed so as to be complementary to the plug region in such a way that a plug region of a sandwich panel can be plugged into the mating plug region of another sandwich panel to connect the sandwich panels.

Systems and methods are provided for blade-and-slot panel affixation. One embodiment is a method. The method includes cutting a first slot into a first composite panel that includes a core between two facesheets. The first slot penetrates through the core of the first composite panel. The method also includes cutting a second slot into a second composite panel that includes a core between two facesheets. The second slot penetrates through a facesheet of the second composite panel as well as the core of the second composite panel. The method further includes inserting a blade into the first slot, and inserting the blade into the second slot.

A method is provided of bonding a first component to a second component. The method includes: locating the first component against the second component to form an interface between the components, a curable adhesive being provided at the interface; locating a pressurizable, fluid-filled bladder against the first component such that the first component is sandwiched between the second component and the bladder; locating a backing member against the bladder such that the bladder is sandwiched between the backing member and the first component; pressurizing the bladder such that a consolidating pressure is exerted by the bladder on the first component to conform the first component to the second component; and curing the adhesive while the first component is conformed to the second component by the consolidating pressure.