Abstract: Described are shoes, particularly a sports shoe, having an upper, and at least one of an outer sole and a midsole connected to the upper. At least one of the outer sole and the midsole is formed of knitwear. As examples, the upper is also formed of knitwear. In the examples, the knitwear in an area of outer sole and/or the midsole and the knitwear in an area of the upper are formed as one-piece knitwear.

Abstract: Provided is a composite resin composition to be used as a material for a molded article produced by a molding machine. The composite resin composition includes a main ingredient resin 1 and a fibrous filler 2, and the fiber length direction end of the fibrous filler 2 is defibrated. The length of the defibrated portion 3 is 5% or more and 50% or less of the fiber length of the entire fibrous filler 2. The fiber diameter in the defibrated portion 3 of the fibrous filler 2 is 1/1000 or more and 1/10 or less the fiber diameter in the undefibrated portion. The modulus of elasticity of the fibrous filler 2 is higher than the modulus of elasticity of the main ingredient resin 1, and the difference between these moduli of elasticity is within 20 GPa.

Abstract: A mold for casting a micro-scale structure includes an upper surface including a first cavity having a first depth. A negative pattern for an array of micro-scale structures is defined in a surface of the first cavity. The mold includes at least one second cavity having a second depth defined in the cavity outside of the negative pattern for the array of micro-scale structures. The at least one second cavity defines a negative pattern for a standoff of the micro-scale structure. A fabric retaining frame is disposed in the first cavity.

Abstract: The present application relates to a method for manufacturing fiber-reinforced plastic products. This method comprises: preparing a fiber preform on a mold; disposing first and second flow meshes and first and second demolding cloths; sealing the fiber preform to form a vacuum system by pumping; penetrating the resin through the first peel ply via the first flow mesh and impregnates the fiber preform from bottom to top; penetrating the resin through the second peel ply via the second flow mesh and impregnates the fiber preform from top to bottom; and attaining a resin-impregnated fiber perform and finally attaining fiber-reinforced plastic products.

Abstract: A method and apparatus for assembling a suspension. In one embodiment, a method includes altering a temperature of a first suspension component and then pressing the first suspension component and a second suspension component into engagement while the temperature remains substantially altered.

Abstract: A vehicle wire harness assembly is provided that, in addition to carrying electricity to and from a vehicle closure, acts as a tether that provides structural reinforcement to the vehicle closure during a crash event. The vehicle wire harness assembly includes a wire harness having electrical wires and a sheath. The electrical wires have an electrical wire tensile strength. The wire harness includes one or more reinforcing tendons configured such that the electrical wires and the reinforcing tendon(s) have a combined tensile strength that is at least 50 percent greater than the electrical wire tensile strength. Anchors retain the wire harness to a vehicle body and a body panel closure. Each anchor has a pull-out strength of at least 50 pounds.

Abstract: A wind turbine blade and a method of moulding a wind turbine blade tip section. The overall wind turbine blade has an elongate structure extending in a radial sense in a finished wind turbine. The blade comprises a fairing that one is supported along its length by a spar extended along the full length of the fairing from the root end to the tip. The fairing is in two parts with a main part extending from the root for most the of the longitudinal length of the blade and the tip section forming the remainder of the blade.

Abstract: The described bicycle has a frame made of a composite material and defining a monocoque shell which is monolithic, entirely formed of the composite material, and includes: a rear upper portion, a head tube portion, and a rear mounting portion; and first and second side panels each extending between, and integrally formed with, at least the head tube portion at a forward end and the rear upper portion and the rear mounting portion at a rearward end. The first and second side panels are integrally interconnected along their respective top and bottom edges to form a substantially hollow shell structure at least partially enclosing a shell cavity defined between the laterally spaced apart first and second side panels. The hollow shell structure defines a rear opening between the rear upper portion and the rear mounting portion that communicates with the shell cavity.

Abstract: A method of fabricating a reinforcing edge (10?) of a turbine engine blade (70) in which there is provided a blank (10) of the reinforcing edge and an indentation is imprinted in said blank so as to form a rough surface (S). A reinforcing edge (10?) obtained by such a method.

Abstract: A complex-shaped, three-dimensional fiber reinforced composite structure may be formed by using counteracting pressures applied to a structural lay-up of wetted fibers with mechanical features embedded or encapsulated therein. The mechanical features may be located on or at least partially between two or more pressurizable members, which may be internally pressurized within a mold. The mechanical features may operate as bearing plates, attachment fittings, or other structural elements. Assemblies of pressurizable members, fiber plies and mechanical features may be arranged to create complex composite structures with predefined load paths, enhanced structural capability or both.

Abstract: Cauls and methods of using cauls to produce composite articles are provided. The caul transitions from a rigid state to an elastomeric state and from an elastomeric state to a rigid state in response to a stimulus and has a reinforcement density of from 100 kg/m3 to 500 kg/m3. Methods of using cauls to produce composite articles involve positioning one or more fiber layers between a caul and a cure mold surface when the caul is in a rigid state. The fiber layers, caul, and cure mold surface may be covered with a sealed barrier and a pressure gradient may be applied. Before, after, or before and after performing the vacuum the fiber layers may be impregnated with resin. The fiber layers may be cured, which may provide a stimulus to transition the caul from a rigid to an elastomeric state, and the composite article is produced.

Abstract: A self-destruction device adapted to be installed in a propeller blade, the self-destruction device including a detector adapted to detect a release of the propeller blade, a warning mechanism adapted to send a release alarm in the event of the detector detecting release of the propeller blade, and a destruction mechanism adapted to destroy the propeller blade in the event of receiving a release alarm from the warning mechanism. An engine and an aircraft are also provided.

Abstract: For forming profile elements, in particular trapezoidal or ?-shaped profile elements, from a multilayer stacking of pre-impregnated fibers, the stacking is moved in feed direction with feed speed by sets of conveyor belts which engage with the upper and lower surfaces of the lateral edge sections of the stacking and hold the edge sections in a starting plane. The sets of conveyor belts are arranged so that the distance between the sets engaging with opposite edge sections decreases in feed direction. To conduct the forming step a middle portion of the stacking is moved over a ramp upwardly inclined in feed direction with respect to the starting plane.

Abstract: In one aspect, a method for manufacturing a spar cap for a wind turbine rotor blade may generally include stacking a plurality of plates together to form a plate assembly, wherein each of the plates is formed from a fiber-reinforced composite including a plurality of fibers surrounded by a thermoplastic resin material. The method may also include positioning the plate assembly relative to a mold defining a mold surface, wherein the mold surface is shaped so as to correspond to at least one blade parameter of the wind turbine rotor blade. In addition, the method may include applying pressure to the plate assembly via the mold such that at least a portion of the plate assembly conforms to the shape of the mold surface.

Abstract: A method includes the step placing composite laminate material onto a three dimensional forming tool with an external surface and at least four junctures associated with the external surface. Each juncture is positioned between two adjacent planar surfaces in which each of the two adjacent surfaces extend in a different plane, the junctures converge and each juncture defines a line of direction. The three dimensional forming tool arranged in a two dimensional pattern, has the lines of direction and the two adjacent planar surfaces positioned on opposing sides of each of the at least four junctures are all positioned in a common plane. The line of direction of each of the at least four junctures in the two dimensional pattern converge to a common point. At least one line of direction is not in alignment beyond the common point with another line of direction. Tool apparatus is also provided.

Abstract: The object of the present invention is to provide a gasket forming mold with a structure in which curling of the reversing section of the gasket molding does not occur easily. To achieve said object, the forming mold for integrally forming an endless shaped gasket has forming grooves as cavities in the parting surfaces of the forming mold and the forming grooves have a reversing section in a part thereof. The reversing section has two linear portions and the ends of the two linear portions are connected by an arc-shaped curved section. The two linear portions are arranged at literally-symmetrical positions and are arranged so that a distance therebetween is enlarged little by little from one end toward the other. The ends where said distance is enlarged are connected by the circular arc-shaped curved section.

Abstract: A method of manufacturing a curved profile from a rectilinear preform of pre-impregnated fiber plies. The method includes stacking plies on a deformable mandrel and winding the deformable mandrel and the stacked plies on a bending tool along a rotation axis, the profile comprising a stack of N plies. At least one first section of the profile is arranged along a plane perpendicular to the axis of rotation and at least one second section is arranged in a plane parallel to the axis. The method includes the steps of stacking the N plies of fibers on the deformable mandrel, bending in a single step the N plies sandwiched between the deformable mandrel and the bending tool and polymerizing the bent N plies. The curved profile comprises M plies with fibers oriented at A° relative to a longitudinal direction and M+/?5% plies with fibers oriented at ?A°.

Abstract: There is provided a tampon pledget that includes one or more enhanced features that result in the pledget exhibiting increased bypass leakage prevention. These enhanced features may include, but are not limited to, geometry, absorption, and any combinations thereof. There is also provided one or more methods for constructing a tampon pledget having increased bypass leakage protection.

Abstract: A system for manufacturing a stiffened composite panel may include a stiffener tooling assembly, a caul plate, and a rotatable strongback. The stiffener tooling assembly may include stiffener tooling configured to support a plurality of composite stiffeners. The caul plate may have a layup surface for laying up a composite skin. The strongback may be releasably coupled to the caul plate. The system may include a plurality of hinges each having a fixed hinge portion and a movable hinge portion. The movable hinge portion may be coupled to the strongback for rotation thereof between an open position and a closed position for engagement of the caul plate with the stiffener tooling assembly.

Abstract: An aircraft wing tip device may include a unitized, monolithic leading edge torque box that may be formed of polymer matrix fiber-reinforced material. The leading edge torque box may include a skin that may define a continuous, uninterrupted outer mold line surface extending aftwardly from a winglet leading edge by a distance of at least approximately 60 percent of a local chord length. The leading edge torque box may further include at least one internal component extending between opposing inner surfaces of the skin and being integrally formed therewith.

Abstract: The present invention relates to an intravaginal tampon for feminine hygiene. In particular, it relates to methods for producing such a tampon having relatively deep, penetrating grooves in which adjacent penetrating jaws pass through the same tampon press space during manufacture and to an apparatus useful in making such a tampon as well as the tampons made therewith.

Abstract: A jig for fixing laminated materials, a system for manufacturing bonded laminated materials, and a method of manufacturing bonded laminated materials are provided at a good yield factor and to efficiently manufacture the bonded laminated materials that are pressed and bonded after being laminated without a misalignment of the membranes or deformation of the laminated materials or any deficiency in bonding at the interface. The bonded laminated materials are manufactured by storing materials made of membranes (W) in a housing space (S) formed by a first sheet-shaped member (12), a second sheet-shaped member (22), and a sealing member (30), exhausting the housing space (S) to sandwich the laminated materials (W) between the first and second sheet-shaped members (12, 22) to fix them, and pressing and bonding them by hot-pressing rollers (51) and cold-pressing rollers (52) of a machine (50) for manufacturing the bonded laminated materials while they are fixed.

Abstract: A gas turbine engine 10 is provided with electrical harness rafts 200 comprising electrical conductors embedded in a rigid composite material. The rafts 200 are used to transport electrical signals (which may be, for example power and/or control signals) around a gas turbine engine. Rafts 200 may be connected together and to other components using flexible cables, that may help to accommodate relative movement of the rafts 200, for example through vibration. The rafts 200 are lighter, more compact, and more convenient to handle than conventional electrical harnesses. The rafts 200 may provide a convenient and secure mounting surface for other components/systems of a gas turbine engine, such as EECs and/or fluid pipes.

Abstract: A method for forming a bicycle frame assembly having a number of elongate tubes is disclosed. A two part mold can be used to form a hollow finish part as part of the assembly. The assembly includes a passage that is defined by the elongate member, a partition, and a bridge. The partition isolates the passage from an interior volume of the elongate tube. The bridge extends in a direction normal to an elongate direction of the passage and defines an inlet and an outlet of the passage. The inlet, outlet, and bridge are generally flush with an exterior surface of the elongate tube and provide a passage that cooperates with a flexible connector, such as a cable tie, for securing supplemental structures, such as brake and shift control cables, to the elongate tube of the bicycle frame assembly.

Abstract: A method and apparatus for reinforcing an end portion of a deformable tool configured for use in forming a composite object. An insert may be placed within a hollow portion of the end portion of the deformable tool in which the insert substantially conforms to a cross-sectional shape and a size of the hollow portion of the end portion of the deformable tool. A side of the end portion of the deformable tool may be reinforced by the insert located within the hollow portion of the end portion of the deformable tool during a curing process used to form the composite object.

Abstract: A contoured composite part is made by assembling a preform charge, including aligning a plurality of plies along a preselected contour. The assembled aligned preform charge is then placed in a forming tool, where the charge is formed and cured.

Abstract: A method for producing a part made of a composite material, including a skin and at least one stiffener made of strips, which are in turn made of one or more plies of fibers impregnated with a non-polymerized resin. The method includes the steps of: producing a preform of the part by pulling the strips through a die for shaping and positioning the skin and the stiffeners, a polymerization core being provided between a first strip and a second strip prior to the passage thereof through the die; and pressing the resulting preform in a hot press for a duration dt while applying a pressure P and at a temperature T for polymerizing the resin of the strips in the hot press over a pressing length L that is shorter than the length of the panel.

Abstract: A method of fabricating a wind turbine blade tubular spar, wherein the tubular spar extends along a designated axis, is made of reinforced polymer material having fibers arranged in at least two directions, and a polymer matrix incorporating the fibers, and has two caps and two webs; the method including the steps of: molding and cross-linking at least part of a cap or web in composite material; molding and cross-linking an L-shaped structure, which has two opposite parallel flanges, and at least partly incorporates the previously molded, cross-linked cap or web of composite material; repeating the above steps to mold and cross-link a further L-shaped structure; and joining the two cross-linked, L-shaped structures, with the flanges positioned facing in pairs.

Abstract: A bicycle component with reinforced structure and a manufacturing method thereof are disclosed. The bicycle component includes a hollow main body and a foam material. The main body is manufactured by stacking plural carbon fiber prepreg layers and provided with a force bearing area. The foam material is disposed on the force bearing area and wrapped by the carbon fiber prepreg layers. Therefore, the present invention improves the structural strength of the bicycle component, lightens the weight of a bicycle made of the bicycle components, and provides a greater controllability of the bicycle.

Abstract: A fabrication method and a fabrication device capable of fabricating medium-scale mass production parts. The method of fabricating a composite material hollow part includes: holding a tool on a frame using a holding section that maintains a gap between the tool and the frame, placing a prepreg on the tool, covering the tool and the prepreg using a highly stretchable sheet, securing the highly stretchable sheet and the frame with a securing jig so that tension is applied to the highly stretchable sheet from the top portion of the prepreg where the highly stretchable sheet contacts the prepreg at the highly stretchable sheet and the outer periphery of both the tool and the prepreg to the edges of the highly stretchable sheet, thereby forming an enclosed space that houses the tool and the prepreg, and subsequently evacuating the inside of the enclosed space to wrap the prepreg around the tool.

Abstract: A method of fabricating an element (25) out of composite material, the element comprising three arms (22, 23, 24) arranged in a triangle. The method comprises the operations of: fabricating a three-dimensionally woven preform from reinforcing fibers and including through slots defining two arms (22, 23) and two half-arms that are all parallel and contiguous in pairs, each arm (22, 23) having one end whereby it is connected to a half-arm and another end whereby it is connected to the other arm (22, 23); shaping the preform by deploying it and by uniting its two half-arms in order to give it a triangle configuration; securing together the half-arms by stitching with reinforcing fibers; and injecting resin into the preform and polymerizing the resin.

Abstract: An inverted tube bike frame with bottle opener gusset system is a bicycle frame with the top tube and down tube having a heightened profile with concave sidewalls and a bottle opener gusset strengthening the joint between the seat tube and the top tube. The top tube has a downwardly curved design for added mechanical strength. Other tube-members of the frame have an elongated elliptical cross-section for increased strength and impact damage resistance. The wheel base is wider than that of a standard bicycle adding to forward movement stability and rider comfort. The design of the frame provides added strength and increased frame life with rugged service.

Abstract: A method for producing a curved section piece from a rectilinear preform of preimpregnated fiber layers includes stacking layers on a deformable mandrel and winding the mandrel and bending the stacked layers on a bending tool on a rotation axis in a single phase and polymerizing the bent layers. The section piece includes a stack of N layers, at least a first portion of which is placed in a plane perpendicular to the rotation axis (X) and at least one second portion parallel to the axis (X) including at least one layer of fibers oriented at 0° along the length of the perform. The N fiber layers are stacked on the mandrel. A neutral fiber is placed on a portion of the mandrel closer to the rotation axis (X) than the last layer of fibers oriented at 0° stacked on the 0second portion parallel to the rotation axis (X).

Abstract: A spherical annular seal member 35 for use in an exhaust pipe joint has a spherical annular base member 33 which is defined by a cylindrical inner surface 29 forming a through hole 28, a partially convex spherical sliding surface 39, and annular end faces 31 and 32 on large- and small-diameter sides of the partially convex spherical sliding surface 39.

Abstract: A spherical annular seal member 35 for use in an exhaust pipe joint includes: a spherical annular base member 33 defined by a cylindrical inner surface 29, a partially convex spherical surface 30, and large- and small-diameter side annular end faces 31 and 32 of the partially convex spherical surface 30; and an outer layer 34 formed integrally on the partially convex spherical surface 30 of the spherical annular base member 33.

Abstract: A method for producing a curved profile from a rectilinear preform of preimpregnated fiber webs, including stacking webs on the deformable mandrel and winding the deformable mandrel and the stacked webs on a bending tool along an axis of rotation (X), the profile including a stack of N webs, at least one first part of the profile being positioned in a plane perpendicular to the axis of rotation (X) and at least one second part parallel to the axis (X) whereof a face can be in contact with the bending tool. The method includes stacking the N fiber webs on the deformable mandrel, generating a heat gradient between the face and the rest of the preform that is hotter than the face, bending, in a single phase, the N webs inserted between the deformable mandrel and the bending tool, and polymerizing the N bent webs.

Abstract: A seat post for a frame, the seat post comprising, a tubular section having a circumference; the tubular section including one or more slots; and the one or more slots extending through a portion of the circumference of the tubular section.

Abstract: A structure such as a containment case (2) for a gas turbine engine (1) comprises an annular housing (3) made of composite material. A sleeve-like flange unit (4) is fitted onto an end of the housing (3) and is mechanically joined thereto by a first portion (31, 32, 33) of the composite material of the housing which projects into a recess (411) of the flange unit (4). This reduces or eliminates the need to use mechanical fasteners to connect the housing (3) to the flange unit (4).

Abstract: A method having the following steps: feeding a plastic material in the area of an inner surface of the mold, conforming the material to the inner surface of the mold, feeding a tubular film into the mold so that the material is positioned between an outer surface of the tubular film and the mold, expanding the tubular film using pressure and/or a vacuum, applying a pressure above atmospheric pressure and/or heating the mold so that the material is partly or completely melted and is adapted to conform to an inner contour of the mold and an outer contour of the expanded tubular film. The tubular film is shaped before it is fed into the mold. The invention further relates to a tubular film (1) and a method for manufacturing the same.

Abstract: A pre-form CMC cavity and method of forming pre-form CMC cavity for a ceramic matrix component includes providing a mandrel, applying a base ply to the mandrel, laying-up at least one CMC ply on the base ply, removing the mandrel, and densifying the base ply and the at least one CMC ply. The remaining densified base ply and at least one CMC ply form a ceramic matrix component having a desired geometry and a cavity formed therein. Also provided is a method of forming a CMC component.

Abstract: A method of press moulding a moulding material to form a moulded part of fibre-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a first moulded surface of the moulded part and the lower mould part having a second moulding surface for moulding a second moulded surface of the moulded part; ii. providing a multilaminar panel of moulding material comprising at least one layer of fibres and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface and a dry fibre layer of the multilaminar panel forming the second major surface; iii.

Abstract: A method of press moulding a moulding material to form a vehicle body panel of fibre-reinforced resin matrix composite material, the vehicle body panel having a front A-surface and a rear B-surface, the method comprising the steps of: i. providing a heated mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a front A-surface of the vehicle body panel and the lower mould part having a second moulding surface for moulding a rear B-surface of the vehicle body panel; ii. providing a multilaminar panel of moulding material comprising at least one layer of fibres and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces, a surface resin layer of the multilaminar panel being at or adjacent to the first major surface; iii. locating the moulding material in the mould tool; iv. closing the mould tool to define a substantially closed mould cavity containing the moulding material; v.

Abstract: A method of press moulding a moulding material to form a moulded part of fibre-reinforced resin matrix composite material, the method comprising the steps of: i. providing a mould tool having a lower mould part and an upper mould part, the upper mould part having a first moulding surface for moulding a first moulded surface of the moulded part and the lower mould part having a second moulding surface for moulding a second moulded surface of the moulded part; ii. providing a multilaminar panel of moulding material comprising at least one layer of dry fibres and at least one layer of resin, the multilaminar panel having first and second opposite major surfaces; iii. locating the moulding material in the mould tool; iv.

Abstract: A method for producing a textile preform includes manufacturing a multi-layer fiber fabric, which includes a first flange portion and a web portion connected to the first flange portion, deforming a first fiber layer of the first flange portion with respect to the web portion, such that the first fiber layer is at a first flange portion angle to the web portion, a web height of the web portion being set in a variable manner during the deformation of the first fiber layer, and depositing a unidirectional fiber fabric only on the deformed first fiber layer of the first flange portion.

Abstract: A method of making a sandwich-type, compression-molded, composite component having improved surface appearance is provided. Reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core of a blank or stack of sandwich materials are heated to a softening temperature of the thermoplastics. The heated blank or stack is allowed to cool in the mold cavity until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal core cavities. Air in the sealed cavities urges softened portions of the sheets and portions of the core inwardly towards the cavities of the core as the air in the cavities cools to inhibit debossing and improve surface appearance of a first outer surface of the blank or stack.

Abstract: Tools for forming a corrugated structure from a pliable blank include a plurality of forming blocks that laterally move relative to each other, a compaction mechanism configured to selectively conform the pliable blank to the forming blocks, and a block translating mechanism configured to reconfigure the tool from a pre-formed configuration to a post-formed configuration, in which the forming blocks are positioned closer together than when the tool is in the pre-formed configuration. Associated systems, methods, and apparatuses also are disclosed herein.

Abstract: A die for producing pressed, fiber-reinforced plastic components, as well as a method for producing the plastic component, and the plastic component itself. The plastic components comprising at least two structural parts which overlap one another a pressing direction such that the die comprises at least one upper die portion formed with a pressing unit for applying a pressing force in the pressing direction, and at least one lower die portion which cooperates with the upper die portion to form a cavity in which the plastic component is formed. A die insert is fitted in the die and can move by and with the upper die portion and is designed to transmit the pressing force to the at least one structural part of the plastic component which is overlapped by the other structural part of the plastic component in the pressing direction.

Abstract: A method for forming a ceramic matrix composite (CMC) component for gas turbine engines. The method contemplates replacing a plurality of plies with insert material. The insert material can be partially cured or pre-cured and applied in place of a plurality of small plies or it may be inserted into cavities of a component in the form of a paste or a ply. The insert material is isotropic, being formed of a combination of matrix material and chopped fibers, tow, cut plies or combinations thereof. The use of the insert material allows for features such as thin edges (650) with thicknesses of less than about 0.030 inches and small radii such as found in corners (680, 710). The CMC components of the present invention replace small ply inserts cut to size to fit into areas of contour change or thickness change, and replace the small ply inserts with a fabricated single piece discontinuously reinforced composite insert, resulting in fewer defects, such as wrinkles, and better dimensional control.

Abstract: A method of manufacturing a component by molding is provided. A mold has a mold surface representing a negative image of the component. The mold has openings in the mold surface. Flow channels extending from the openings in the mold surface and are connectable to a suction device. Further, the mold has a periphery delimiting the mold surface. A bag is fixed to the periphery of the mold. The bag is inflated to a pressure level above ambient pressure. The pressure is released from the bag while sucking the bag to the mold surface using the suction device. Fabrics are layered onto the bag while the bag is kept sucked to the mold surface. Resin is introduced into the fabrics and then the resin is cured.

Abstract: The present disclosure is related to a method for producing a cellular panel which includes a cellular structure sandwiched between first and second stiff skins. The method includes the following steps: preparing at least two blocks of cellular material; disposing the two blocks on a base ply of dry fabric, while maintaining a space between the two blocks; folding the base ply around the two blocks so as to envelop the two blocks; filling in the space with a reinforcing ply; covering the base ply with a covering ply, on a side where the reinforcing ply has been introduced; injecting resin to an assembly obtained in the previous step; and curing the assembly.