A method of fabricating a panel includes laying up a first laminate on a tooling surface, laying a first layer of thermoplastic on an inner surface of the first laminate, laying a large cell carbon core on the first layer of thermoplastic, laying a second layer of thermoplastic across the large cell carbon core, laying a second laminate on the second layer of thermoplastic, creating a sealed core pocket by bonding the edges of the first and second layers of the thermoplastic surrounding a perimeter of the core, increasing pressure within the core pocket, increasing pressure on the outer surface of the second laminate, heating the panel to a desired curing temperature, and maintaining the increased pressures and temperature for a desired curing duration.

A marine deck member with enhanced surface traction and the process for forming the same. The marine deck member comprises a sandwich-type composite panel made by a compression molding process. In such a process, the panel is made by subjecting a heated stack of layers of material to cold-pressing in a mold. The cellular core has a 2-D array of cells, each of the cells having an axis substantially perpendicular to the outer surfaces, and extending in the space between the layers or skins, with end faces open to the respective layers or skins. The surface traction of this type of composite panel can be enhanced for marine deck applications by controlled debossing, or embossing, of the first skin while it cools in the compression mold. The debossing effect can be effected by applying pressurized gas, e.g., pressurized air, onto the outer surface of the first skin while in the compression mold. The embossing can be effected by applying vacuum pressure on the outer surface of the first skin while in the compression mold.

A foam sheet core, including a plurality of foam sheet walls defining an array of hollow cells, wherein the plurality of foam sheet walls are bonded together to form the array of hollow cells, each of the plurality of foam sheet walls has a thickness from about 0.002 inches to about 0.08 inches, and each of the plurality of foam sheet walls has an average height from about 0.05 inches to about 5 inches.

A method for manufacturing a cellular structure having first and second faces, rows of cells each alternatingly having first cells, which are open in the direction of the first face, second cells, which are open in the direction of the second face, and also third cells formed between each row of cells, each row of cells comprising first and second strips of material placed against one another. The first and second strips of material are shaped by bending. By contrast to plastic deformation, shaping by bending makes it possible to expand the choice of materials and thicknesses for the first and second strips of material. An advantageous cellular structure is thus obtained as well as an acoustic absorption coating comprising such a cellular structure.

A method and a mineral wool product include a multiple of lamellae, such as a sandwich panel core. The product includes a plurality of lamellae cut from a mineral wool web, and bonded together by applying an adhesive on the surfaces of two adjacent lamellae to form a web-like product, wherein the adhesive comprises at least one hydrocolloid.

The present invention provides a laminated plate capable of not only achieving a reduced weight and an increased rigidity but also improving a sound absorbing performance, and a method for manufacturing the same. A laminated plate (1) is supposed to include a core layer (2) including a plate-shaped paper honeycomb structure (4) and a pair of fiber reinforcement layers (3) sandwiching the paper honeycomb structure (4) from both sides in a thickness direction and integrated with the paper honeycomb structure 4. The through-holes (5) of the paper honeycomb structure (4) are filled with a foam resin (6), and the core layer (2) is made up of the paper honeycomb structure 4 and the foam resin (6) filled in the through-holes (5). When the foam resin (6) is filled in the through-holes (5) of the paper honeycomb structure (4), the foam resin plate (6A) is pushed into the through-holes (5) as a filling material by utilizing a compression force of a mold (11).

The present invention addresses the problem of providing a method for molding, using a honeycomb core, a composite material structure that is high-quality, low cost, and leaves less voids. The present disclosure addresses the problem of providing a method for molding, using a honeycomb core, a composite material structure with which it is possible to reduce dimples in a composite material skin at low cost. According to a method for molding a composite material structure of the present disclosure, an uncured composite material honeycomb sandwich panel in which prepreg is laminated on upper and lower surfaces of a honeycomb core via an adhesive is covered with a vacuum bag and placed in an autoclave. After that, the vacuum bag is evacuated and, while the evacuation is being continued, is heated and pressurized by the autoclave to cure a matrix resin of the prepreg and achieve adhesion to the honeycomb core.

A method of manufacturing sheeting is provided, the method including the steps of forming multiple recesses in a symmetrical repeat pattern on a sheet of material, extruding a molten material to form an upper outside wall and a lower outside wall, interposing the formed sheet between the upper outside wall and the lower outside wall, and fixing the interposed sheet to the upper outside wall and the lower outside wall. Also provided is sheeting having an upper outside wall and a lower outside wall and an interposed sheet fixed between the outside walls. The interposed sheet includes multiple recesses in a symmetrical repeat pattern, where the upper and lower outside walls are, or the interposed sheet is, manufactured from a material which includes a polymeric material.

A load structure may include a panel, a layer of fibrous material, and/or an over mold coating. The panel may include a core. The layer of fibrous material may be disposed on a first side of the panel and an edge of the panel. The over mold coating may be disposed on a second side of the panel.

A laminated structure includes a front facesheet, a rear facesheet and a core arrangement disposed there between. The core arrangement includes a plurality of ribs, the ribs disposed so as to form walls defining a reticulated lattice of cells. The ribs have a thickness in a first direction and a height in a second direction approximately orthogonal to the facesheets and to the first direction that extends between the first adhesive joint and the second adhesive joint, the height being at least 100× larger than the thickness. The core arrangement is bonded to the front facesheet by curing a first adhesive joint and bonded to the rear facesheet by curing a second adhesive joint, the first adhesive joint and the second adhesive joint being concurrently cured (co-cured) under pressure.