Sandwich-structured noise-attenuating and/or structural panels and methods of manufacturing such panels using ultrasonic welding are described. The method includes: receiving a backing member, a sheet and a cellular structure; assembling the cellular structure between the backing member and the sheet; and ultrasonically welding the backing member and the sheet together.

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.

Provided are sandwich panel assemblies. Specifically, a sandwich fuselage panel comprises an outer skin member and an inner skin member coupled to the outer skin member at a first edge and a second edge, forming a cavity comprising a center portion, a first transition portion extending from the center portion to the first edge, and a second transition portion extending from the center portion to the second edge. A cured foam adhesive may occupy each of the first transition portion and the second transition portion of the cavity. A core structure, such as a honeycomb structure may occupy the center portion of the cavity. Alternatively, the cured foam adhesive may occupy the center portion of the cavity. The density of the cured foam adhesive in the transition portions may gradually increase from the center portion to the respective edge. The cured foam adhesive may comprise a polymer foam adhesive.

A substructure and its method of use eliminates core crush during the manufacturing of a hybrid sandwich-structured composite panel. The substructure is used in the manufacturing of the hybrid sandwich-structured composite panel by positioning a core of the composite panel in a cavity of the substructure and positioning the substructure and the core between layers of composite material where the substructure protects the core from core crush as the hybrid sandwich-structured composite panel is subjected to vacuum pressure and heat during autoclaving and then cured.

Stiffened skin panels comprise alternating truss core portions and solid laminate portions sandwiched between inner and outer facesheets, all formed from a fiber reinforced thermoplastic. The components of the panels are co-consolidated using induction heating. The panels are stiffened with spars fastened to the solid laminate portions.

Sandwich-structured noise-attenuating and/or structural panels and methods of manufacturing such panels using ultrasonic welding are described. The method includes: receiving a backing member, a sheet and a cellular structure; assembling the cellular structure between the backing member and the sheet; and ultrasonically welding the backing member and the sheet together.

A molded composite battery enclosure containing top and bottom composite covers having a formed cross member arranged between the top and bottom covers. The cross member is a formed member having a surface portion secured to a reinforcement section in one of the composite covers. The reinforcement section is a buildup of resin and fibers on or near a surface of one of the covers that provides a rigid joining point for securing internal battery enclosure components and vehicle components to the composite covers of the battery enclosure.

A molded composite battery enclosure containing top and bottom composite covers having a formed cross member arranged between the top and bottom covers. The cross member is a formed member having a surface portion secured to a reinforcement section in one of the composite covers. The reinforcement section is a buildup of resin and fibers on or near a surface of one of the covers that provides a rigid joining point for securing internal battery enclosure components and vehicle components to the composite covers of the battery enclosure.