A composite structure includes a foam core formed from a first polymer and between about 0.5 wt. % and about 2.5 wt. % graphene. The foam core has an average pore size between about 25 μm and about 75 μm, and a cell density between about 4×10.sup.6 cells/mm.sup.2 and about 6×10.sup.6 cells/mm.sup.2. Also, an overmolded skin formed from a second polymer and between about 0.25 wt. % and about 5.0 wt. % graphene is disposed on the foam core. A method of manufacturing a composite structure includes injection molding a foam core from a first polymer containing between about 0.25 wt. % and about 5.0 wt. % graphene, and injection molding an overmolded skin from a second polymer containing graphene between about 0.25 wt. % and about 5.0 wt. % graphene.

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.

An electrically decoupled jet engine. The electrically decoupled jet engine includes a combustion chamber which creates a toroidal flow of air and a rotational electric motor which drives a fuel supply into the combustion chamber. The toroidal flow of air is mixed with the fuel and combusted in the combustion chamber to create thrust.

A composite structural panel for use in bridge structures, and method of manufacturing same, comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross-sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.

A method of repairing a core stiffened structure, including removing a damaged portion of the core stiffened structure; bonding a shelf onto a first core member; bonding a second core member to a shelf; and securing a skin patch over the second core member.

A battery assembly according to an exemplary aspect of the present disclosure includes, among other things, a battery array and a foam shell that surrounds the battery array.

A method for making a foam component is provided and includes inserting a foam material into a cavity of a mold having a top plate and a bottom plate, heating the foam material to cause the foam material to expand, and moving one of the top plate and the bottom plate relative to the other of the top plate and the bottom plate as the foam material expands and contacts the one of the top plate and the bottom plate to cause the foam material to fold over on itself within the cavity.

Low-density thermoplastic expandable microspheres are disclosed. Various low-density structures, in particular, sandwich panels, based on foam prepared from the low-density microspheres, are also disclosed. Process of preparing low-density polymeric microspheres, per se, and the corresponding low-density structures, based on the microsphere foam, are also disclosed.

A battery assembly includes a battery array and a foam shell that surrounds the battery array. The battery array may be housed within a foam shell, and a barrier can be secured to the foam shell to establish a battery assembly. The battery assembly may then be secured to a vehicle body.

A structural panel and method of fabricating and manufacturing same comprises a top panel and a bottom panel separated by and attached to at least one, but preferably a plurality, of structural composite preforms which may be fabricated by a continuous manufacturing process and may be saturated by resin using a continuous wetting process. The composite preforms may take any cross sectional shape but are preferably trapezoidal. The top and bottom panels may be fabricated from a plurality of layers of woven fabric layers and non-woven fabric layers which are saturated with a resin that is subsequently cured using cure processes known in the art. The composite structural panel of the invention is usable as a flat structural member for use as bridge decking, ramps, trestles, and any application requiring a structural panel.