Abstract:
An apparatus includes a matched die mold including a male die mold and a female die mold wherein the male die mold includes a first contoured surface and the female die mold includes a second contoured surface. The apparatus further includes a frame which defines an opening wherein the frame is positioned between the male die mold and the female die mold such that the frame is adapted to position a film layer across the opening and the opening is positioned in alignment with at least one of the first contoured surface and the second contoured surface.
Abstract:
A composite laminate structure includes a cellular core and a first laminate layer coupled to the cellular core. The first laminate layer includes a first thermoplastic layer and a first fiber-reinforced polymer layer, where a first surface of the first fiber-reinforced polymer layer is thermally consolidated to a second surface of the first thermoplastic layer. A first surface of the first thermoplastic layer is directly in contact with and bound to a first surface of the cellular core by temperature reduction of the first thermoplastic layer below a glass transition temperature of the first thermoplastic layer while the cellular core is pressed against the first thermoplastic layer when the first thermoplastic layer is above the glass transition temperature of the first thermoplastic layer and the cellular core is below a temperature where materials of the cellular core flow or degrade.
Abstract:
Disclosed herein is a reinforced panel. The reinforced panel is produced by a process that comprises applying a reinforcing fiber material, comprising a first polymeric material, to only a portion of a panel sheet, comprising a second polymeric material. The process also comprises, after applying the reinforcing fiber material to the panel sheet, thermoforming both the second polymeric material of the panel sheet and the first polymeric material of the reinforcing fiber material. The thermoforming integrally couples the panel sheet with the reinforcing fiber material to produce the reinforced panel by fusion bonding the first polymeric material with the second polymeric material. The reinforced panel includes one or more reinforced portions, defined by the reinforcing fiber material, and one or more non-reinforced portions, defined between the reinforcing fiber material.
Abstract:
A thermoforming system and related methods for manufacturing thermoplastic parts, such as interior panels for aircraft, may include a roll-to-roll operation and a forming press having at least one selectively rotatable tool. The rotatable tool, which may include a mold and/or a die, may be multifaceted, such that different faces of the tool have different mold arrangements for different forming characteristics.
Abstract:
Lighting panels and methods of manufacturing lighting panels are described. An example lighting panel includes a substrate that has a planar surface, electrically conductive traces printed onto the planar surface of the substrate, and light sources mounted onto the electrically conductive traces at mounting positions such that the electrically conductive traces form an electrical interconnection between selected ones of the electrically conductive traces and associated ones of the light sources. The lighting panel also includes a polymer sheet provided over the light sources, and a composite base upon which a stack-up of the substrate with the printed electrically conductive traces, the light sources, and the polymer sheet is applied. The light sources are embedded into the composite base and are also flush with a top surface of the stack-up, and the substrate is also embedded into the composite base underneath the light sources at the mounting positions.
Abstract:
Lighting panels and methods of manufacturing lighting panels are described. An example lighting panel includes a substrate that has a planar surface, electrically conductive traces printed onto the planar surface of the substrate, and light sources mounted onto the electrically conductive traces at mounting positions such that the electrically conductive traces form an electrical interconnection between selected ones of the electrically conductive traces and associated ones of the light sources. The lighting panel also includes a polymer sheet provided over the light sources, and a composite base upon which a stack-up of the substrate with the printed electrically conductive traces, the light sources, and the polymer sheet is applied. The light sources are embedded into the composite base and are also flush with a top surface of the stack-up, and the substrate is also embedded into the composite base underneath the light sources at the mounting positions.
Abstract:
Described herein is a composite panel that includes a first layer made from an electrically non-conductive material. The composite panel also includes a resistance heater printed onto the first layer. Further, the composite panel includes a second layer adjacent the resistance heater, the resistance heater being positioned between the first layer and the second layer. The second layer is made from an electrically non-conductive material.
Abstract:
An apparatus comprises a composite sandwich panel, a seal, and a hinge. The composite sandwich panel has a first edge in a first over-crush edge region, wherein a thickness of the composite sandwich panel decreases within the first over-crush edge region in a direction towards the first edge. The seal is bonded to the first over-crush edge region of the composite sandwich panel and extending past the first edge. The hinge is connected to the composite sandwich panel such that an axis of rotation of the hinge is positioned over the first over-crush edge region of the composite sandwich panel.
Abstract:
A method for making a structural sandwich panel includes the steps of positioning a first and second thermoplastic skin elements in overlying relationship with respect to a heated male and heated female die molds respectively. A first pressure reduction is applied between the first thermoplastic skin element and the heated male die mold and a second pressure reduction is applied between the second thermoplastic and the heated female die mold. A core panel element is positioned between the heated male die mold and the heated female die mold wherein the core panel element has a first adhesive on a first side and has a second adhesive on a second opposing side. The male and female die molds are closed and exert a pressure onto the core panel element to secure the first and second thermoplastic skin elements to the core panel element and form the core panel element.
Abstract:
A composite laminate structure includes a cellular core and a first laminate layer coupled to the cellular core. The first laminate layer includes a first thermoplastic layer and a first fiber-reinforced polymer layer, where a first surface of the first fiber-reinforced polymer layer is thermally consolidated to a second surface of the first thermoplastic layer. A first surface of the first thermoplastic layer is directly in contact with and bound to a first surface of the cellular core by temperature reduction of the first thermoplastic layer below a glass transition temperature of the first thermoplastic layer while the cellular core is pressed against the first thermoplastic layer when the first thermoplastic layer is above the glass transition temperature of the first thermoplastic layer and the cellular core is below a temperature where materials of the cellular core flow or degrade.