Method and apparatus for forming a reinforcement panel, method for forming a reinforcement component

Abstract

The present application relates to methods and apparatus for forming a reinforced panel, methods of forming a reinforcing component. A method of forming a reinforced panel can include engaging a reinforcing component having a lapping surface with a first portion of a heated press; engaging an uncured panel component with an opposing second portion of the press; the panel component having a lapping surface configured complementarily with respect to the lapping surface of the reinforcing component; treating the lapping surface of the reinforcing component such that the lapping surface is reactive to co-bond with the panel component; actuating the press to direct the first and second portions of the press against one another such that the lapping surfaces complementarily engage under pressure; and heating the first and second portions of the press to a cure temperature associated with the panel component to co-bond the lapping surfaces of the reinforcing component and the panel component together substantially simultaneously, cure the panel component, and form a reinforced panel.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to a reinforced panel component for an aircraft. More particularly, the present disclosure relates to a method and apparatus for forming a reinforced panel component. BACKGROUND

[0002] Aircraft typically include a fuselage that can be viewed as a substructure to which skin panels are attached to form a smooth aerodynamic outer surface. The wings of an aircraft also include a substructure that is covered with skin panels. The substructure can include stringers that, along with longerons, frames, ribs, spars, etc., form a structural framework. The skin panels are typically light and thin to minimize the weight of the aircraft and increase its payload and range. Because the skin panels are thin, they are typically flexible and need to be reinforced in conjunction with the substructure to avoid adverse movement, bending, and vibration of the skin panels during flight.

[0003] Typically, reinforcement of the skin panels is achieved by bonding the stringers to the skin panels. However, bonding the stringers and the skin panels requires multiple processing cycles, which is both time consuming and expensive. Therefore, there is a need to reduce the cycle time and cost of bonding the stringers to the skin panels, while also keeping the number of parts and weight to a minimum in instances where the stringers are used to reinforce the skin panels. SUMMARY

[0004] One example of the present disclosure relates to a method of forming a reinforced panel component of an aircraft or any similar application. As used herein, "reinforced panel component," "reinforced panel," and "reinforced component" all refer to the same element. In a particular example, the method of forming a reinforced panel component includes applying heat and stress to substantially simultaneously (e.g., at the same time or at a minimal difference in time) bond together the overlapping faces of a reinforcing component and a panel component, and cure the panel component to form a reinforced panel component. Bonding together the overlapping faces substantially simultaneously and curing the panel component advantageously reduces the typical cycle time and cost of bonding a reinforcing component (e.g., a composite stringer) to a panel component (e.g., a composite skin panel), while also keeping the number of parts and the weight of the parts to a minimum. For example, in one example, the typical cycle time of about 8-10 hours using an autoclave is reduced to 20-50 minutes using the apparatus and method disclosed herein.

[0005] Accordingly, in one example, the present disclosure provides a method of forming a reinforced panel, the method comprising: engaging a reinforcement component and a first portion of a heated press, the reinforcement component having a lapping surface; engaging an uncured panel component with an opposing second portion of the press, the panel component having a lapping surface complementarily configured relative to the lapping surface of the reinforcement component; treating the lapping surface of the reinforcement component such that the lapping surface is reactive for co-bonding with the panel component; actuating the press to direct the first and second portions of the press against one another such that the lapping surfaces of the reinforcement and panel components complementarily engage under pressure; and heating the first and second portions of the press to a temperature associated with curing the panel component to co-bond the lapping surfaces of the reinforcement and panel components together substantially simultaneously, cure the panel component, and form the reinforced panel.

[0006] In another example, the present disclosure also provides a method of forming a reinforced component, the method comprising: positioning a first component formed of a consolidated material on a first side of a heated press, the consolidated material having a lapping surface; positioning a second component formed of a non-consolidated material on an opposing second side of the heated press, the non-consolidated material having a lapping surface complementarily configured relative to the lapping surface of the consolidated material; treating the lapping surface of the consolidated material such that the lapping surface is reactive for co-bonding with the non-consolidated material; actuating the press to direct the first and second sides of the press against one another such that the lapping surfaces of the consolidated and non-consolidated materials complementarily engage under pressure; and heating the first and second sides of the press to a curing temperature associated with the non-consolidated material to co-bond the lapping surfaces of the consolidated and non-consolidated materials together substantially simultaneously, cure the non-consolidated material, and form the reinforced component.

[0007] In another example, the present disclosure also provides an apparatus for forming a reinforced panel, the apparatus comprising: a first planar platen having a planar surface; a second planar platen having a planar surface adapted to engage a panel component, the second planar platen being co-operable with the first planar platen to apply pressure therebetween; and an intermediate insert adapted to engage a reinforcement component, the intermediate insert having a planar first surface co-engageable with the planar surface of the first or second planar platen and an opposing second surface co-engageable with and conformal to the reinforcement component such that pressure applied to the reinforcement and panel components between the first and second planar platens is evenly distributed across the reinforcement component, wherein at least the intermediate insert and the first or second planar platen are heated.

[0008] These and other features, aspects, and advantages of the present disclosure will become evident to those skilled in the art from a reading of the following detailed description, taken in conjunction with the accompanying drawings. The present disclosure includes any combination of two, three, four, or more features or elements recited in any one or more of the dependent claims or in the description of the state of the art, whether explicitly stated or not, and whether in the specific examples or not. The present disclosure is intended to be read generically, and thus, any individual feature or element of the present disclosure should be considered intended, i.e., combinable, in respect of any aspect and embodiment thereof, unless the context of the present disclosure clearly indicates otherwise. BRIEF DESCRIPTION OF DRAWINGS

[0009] Having thus described the examples of the present disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

[0010] Figure 1 A reinforced panel according to some examples of the present disclosure is shown;

[0011] Figure 2 An apparatus for forming a reinforced panel according to some examples of the present disclosure is shown;

[0012] Figure 3 A method of forming a reinforced panel according to some examples of the present disclosure is shown; and

[0013] Figure 4 A method of forming a reinforced component according to some examples of the present disclosure is shown. DETAILED DESCRIPTION

[0014] Hereinafter, some examples of the present disclosure will now be described more fully with reference to the accompanying drawings, in which some, but not all examples of the present disclosure are illustrated. Indeed, the various examples of the present disclosure can be embodied in many different forms and should not be construed as limited to the examples set forth herein; rather, these examples are provided so that this disclosure will be thorough and complete, and fully convey the scope of the present disclosure to those skilled in the art. For example, no element, component, or instruction or piece of information is implied by the inclusion of a referring section, such as a first, second, etc. element or component, to be the only item of that type; rather, any one or more elements of a type at some time can be the only item of that type. In addition, a reference to something as being on or adjacent to another thing can include that thing being on, adjacent to, and in some embodiments actually connected to the other thing. Similar reference numerals can refer to similar elements throughout the specification.

[0015] Examples of the present disclosure generally relate to a method of forming a reinforced panel component and related apparatus. As Figure 1As shown, for example, the stiffened panel component 100 is formed by the methods and apparatus disclosed herein. In particular aspects, the stiffened panel component 100 includes a cross-section having dimensions / shape dependent on its application in the aircraft structure. While aspects of the present disclosure contemplate any other shape, dimension, type, etc., for example, the stiffened panel component 100 includes a cross-section defining a channel including or excluding a flange (e.g., a "bell" or "hat" shape), a hook shape or "J" shape, or one or more vertical or horizontal components (e.g., a vertical component sandwiched between two horizontal components or an "I" shape, a vertical component with a horizontal component at one end or a "T" shape); as Figure 1 As shown, the stiffened panel component is a hat-shaped stiffened panel component formed by co-bonding the lap faces of the stiffener component and the panel component substantially simultaneously and curing the panel component, described in greater detail below.

[0016] As used herein, in particular aspects, the stiffener component is considered a composite stiffener component, such as a composite stiffener, wherein the composite stiffener component is formed by molding, stamping, etc. of a composite material. The composite material of the stiffener component is composed of or includes a resin reinforced with a reinforcement material. The reinforcement material includes, but is not limited to, man-made or natural fibers, including carbon fibers, glass fibers, glass spheres, mineral fibers, or other reinforcement materials. If fibers are used as the reinforcement material, for example, the fibers are continuous fibers or short fibers and are unidirectional, randomly oriented, or in a woven form, such as, but not limited to, a plain weave, a Dutch weave, a basket weave, or a twill weave. The resin includes, for example, a thermoplastic material, including, but not limited to: polyphenylene sulfide, polyaryletherketone (PAEK), polyetherketoneketone (PEKK), polyetheretherketone (PEEK), polyimide, polyetherimide, polyamide, polyamide-imide, polyester, polybutadiene, polyurethane, polypropylene, polysulfone, polyethersulfone, polyphenylsulfone, polyacrylamide, polyketone, polyphthalamide, polyphenylene ether, polybutylene terephthalate, polyethylene, polyethylene terephthalate, polyester-polyarylate (e.g., ), polytetrafluoroethylene (PTFE), or other thermoplastic resins. Alternatively, the resin includes, for example, a thermoset material, including, but not limited to: epoxy, cyanate ester, benzoxazine, polyimide, bismaleimide, vinyl ester, polyurethane, polyurea, polyurethane / polyurea blend, polyester, or other thermoset resins. Likewise, in particular aspects, the panel component is considered a composite panel component, such as a composite skin panel, wherein the composite panel component is formed of one or more composite materials, including or consisting of a resin reinforced with a reinforcement material as described with reference to the stiffener component, a matrix composite with a polymeric skin, a glass aluminum composite with a polymeric skin, or a titanium aluminum composite with a polymeric skin.

[0017] In some examples, the reinforcement component is considered a non-consolidated component and the panel component is considered a consolidated panel component. More specifically, the respective overlap faces of the reinforcement component and the panel component are co-bonded together and the panel component is cured (e.g., the co-bonding and curing processes are performed substantially simultaneously) such that the reinforcement component and the panel component are consolidated to form a reinforced panel. As used herein, an overlap face is one of two or more surfaces that are in direct or indirect contact with each other and are bonded to each other by one or more of bolting, riveting, welding, soldering, bonding, etc.

[0018] Accordingly, the methods and apparatus disclosed herein advantageously reduce the cost and cycle time associated with forming a lightweight, rigid, reinforced panel component. This is achieved by utilizing a heated press having two platens that are operable together, which enables the reinforcement component and the panel component to be co-bonded to each other at the respective overlap faces when the panel component is cured (e.g., the co-bonding and curing processes are performed substantially simultaneously). By doing so, the independent cycles of curing the panel component and then bonding the reinforcement component and the cured panel component are combined into a single cycle using the heated press.

[0019] Figure 2 An example of an apparatus for forming a reinforced panel in a closed position is shown and generally designated by reference numeral 200. In some examples, the reinforced panel is the reinforced panel 100 shown in Figure 1 or in some other examples the reinforced panel is another type of reinforced panel. In fact, reinforced panels of any size, shape, material, etc. can be formed using the apparatus shown in Figure 2 In some examples, the apparatus 200 includes a heated press having a first portion and an opposing second portion that are joined to each other (e.g., the first and second portions of the press move between an open position and a closed position).

[0020] In some examples, the apparatus 200 includes a first planar platen 202 or first portion having a planar surface 204. A second planar platen 206 or second portion has a planar surface 208 adapted to engage a second component or panel component 210. The panel component 210 is a composite thermoset skin panel composed of fibers (e.g., carbon fibers, particles, etc.) and a polymeric resin matrix. Other composite materials for the panel component 210 are also contemplated. The thermoset skin is hardened by a curing process induced by heating the thermoset skin to a curing temperature, radiation, etc. and this hardening is accelerated by high pressure.

[0021] More specifically, in order to initiate the curing of the thermosetting skin, the second planar plate 206 can be operated in conjunction with the first planar plate 202 to apply pressure therebetween. For example, the two plates 202, 206 are operably engaged or in contact with each other (e.g., by operating each plate simultaneously, operating only one plate, or operating each plate in different instances) such that the applied pressure is a directional normal force on the plate (e.g., the first planar plate 202 applies a normal force on the second planar plate 206, and the second planar plate 206 applies a counter-normal force on the first planar plate 202). The pressure is approximately 50 to approximately 150 pounds per square inch (psi), where in some cases the amount of normal force applied depends on the surface area of ​​the planar plate.

[0022] The intermediate insert or pressing member 212 can engage with the reinforcing member 214. In some instances, the reinforcing member 214 is a composite thermoplastic or thermosetting composite reinforcing member. In the case where the reinforcing member is a composite thermoplastic reinforcing member, the composite thermoplastic reinforcing member softens when heated to the melting temperature associated with the composite thermoplastic material and then hardens upon cooling.

[0023] The intermediate insert or pressing member 212 has a planar first surface or pressing surface 216 capable of engaging with the planar surfaces 204, 208 of the first planar platform 202 or the second planar platform 206, and an opposing second surface 218 capable of engaging with the reinforcing member 214 and conformally thereon, such that the intermediate insert or pressing member 212 is considered to be configured complementary to the opposing planar surfaces 204 or pressing surfaces 208. Figure 2 As shown, the first planar surface 216 of the intermediate insert 212 engages with the first planar platform 202, while the second surface 218 engages with and conforms to the reinforcing member 214. Specifically, the second surface 218 of the intermediate insert 212 has a profile corresponding to the profile of the reinforcing member 214. For example, the profile of the reinforcing member 214 is based on the shape of the reinforcing member 214, wherein the reinforcing member 214 has a cross-section shaped as a "bell," "cap," "I," "J," or "T," such that the second surface 218 has a profile that accordingly accommodates the reinforcing member thus shaped. The configuration of the second surface 218 of the intermediate insert 212 facilitates the uniform distribution of pressure applied to the reinforcing member 214 and the panel member 210 between the first planar platform 202 and the second planar platform 206 across the reinforcing member 214. The device 200 also includes a heating element 220 associated with at least the intermediate insert 212 and the first planar platform 202 or the second planar platform 206. The heating element 220 may be configured to heat at least the intermediate insert 212 and the first plate 202 or the second plate 206 to substantially simultaneously bond the reinforcing member 214 and the panel member 210 together, cure the panel member 210, and form a reinforced panel (e.g., Figure 1of the first planar platen 202 and the second planar platen 206.

[0024] In some examples, the intermediate insert 212 and the first planar platen 202 or the second planar platen 206 are heated by electrical bonding with a power source (not shown) of the apparatus 200 while the intermediate insert 212 and the first planar platen 202 or the second planar platten 206 are operatively engaged with each other and under pressure. For example, actuation of the power source directs an electrical current to a heating element 220, e.g., an electrically heated whip, that is embedded in, integrated with, or otherwise associated with the intermediate insert 112 and / or the first planar platen 202 or the second planar platen 206. The intermediate insert 112 and the first planar platen 202 or the second planar platen 206 are then heated by the heating element 220 to a cure temperature associated with the panel component 210. The cure temperature of the panel component 210 depends on the material of the panel component, where different materials have different cure temperatures. For example, the intermediate insert 212 and the first planar platen 202 or the second planar platen 206 are heated to a temperature of about 250 degrees Fahrenheit (°F) to about 500°F for about 25 minutes to about 50 minutes, where the panel component is a composite thermoset panel component, in order to co-bond the respective overlap faces 222, 224 of the reinforcement component 214 and the panel component 210 substantially simultaneously together, cure the panel component 210, and form a reinforced panel. The cure temperature associated with the panel component 210 is a temperature that is less than a melting temperature associated with the reinforcement component 214. In this manner, heating the panel component 210 and the reinforcement component 214 while curing the panel component 210 does not melt the reinforcement component.

[0025] In some examples, the reinforcement component 214 is treated prior to the first planar platen 202 and the second planar platen 206 being operatively engaged. More specifically, the overlap face 222 of the reinforcement component 214 and / or the overlap face 224 of the panel component 210 are treated by applying a film, an aggressive surface treatment, or the like, such that the overlap faces 222, 224 are active to co-bond with the panel component 210. The type of preparation treatment applied to the overlap faces 222, 224 depends on the material of the reinforcement component 214.

[0026] For example, where the reinforcement component 214 is a composite thermoplastic reinforcement component, a thermoplastic film 226 is applied to the overlap face 222 of the thermoplastic reinforcement component such that the overlap face 222 is active to co-bond with the panel component 210. The thermoplastic film 226 includes polyetherimide (PEI), polyphenylene sulfide, polyimide, polyamide, polyamide-imide, polyester, polybutadiene, polyurethane, polypropylene, polysulfone, polyethersulfone, polyphenylsulfone, polyacrylamide, polyketone, polyphthalamide, polyphenylene ether, polybutylene terephthalate, polyethylene, polyethylene terephthalate, polyester-polyarylate, polytetrafluoroethylene (PTFE), or any combination thereof.

[0027] In another example, when the reinforcing member 214 is a composite thermosetting reinforcing member, an adhesive enhancer film 228 is applied to the overlapping surface 222 of the composite thermosetting reinforcing member 214 and / or an active surface treatment 230 is performed on the overlapping surface 222 of the composite thermosetting reinforcing member 214 to make the overlapping surface 222 active for co-bonding with the panel member 210. The adhesive enhancer film comprises an unfilled portion of advanced epoxy resin. The active surface treatment includes corona treatment, plasma treatment, flame treatment, or the like on the overlapping surface 222 of the composite thermosetting reinforcing member 214 to make the overlapping surface 222 active for co-bonding with the panel member 210.

[0028] In some instances, a suction mechanism (not shown) is used to apply suction to the device 200 to remove any air or volatiles trapped in the uncured panel component 210. The removal of air or volatiles ensures a strong co-bonding between the reinforcing member 214 and the panel component 210, where any air or volatiles would impede a strong and secure co-bonding at the overlapping surfaces 222, 224.

[0029] Accordingly, Figure 2 The apparatus shown provides a reinforcing member 214 and a panel member 210 to be co-bonded during the curing of the panel member 210. In some respects, the time required to do so is shorter than that of conventional bonding methods, thus achieving significant cost savings and efficiency.

[0030] Figure 3 An example of a method for forming a reinforcing panel is shown, wherein the method is generally indicated by reference numeral 300. In some cases, the reinforcing panel is as follows: Figure 1 The panel shown. In addition, using devices (such as...) Figure 2 The device 200 in the middle executes method 300.

[0031] In step 302, the material is shaped (e.g., continuous compression molding (CCM)) or stamped to form a reinforcing member (e.g., Figure 2 Component 214 in the middle). In step 304, the panel components are arranged (e.g., Figure 2 The uncured plate layer in component 210). In step 306, the device (e.g., a heated press) Figure 2 The apparatus 200) is preheated to a preheating temperature, which is lower than the curing temperature associated with the panel component. For example, the press is preheated to approximately 225°F to approximately 475°F.

[0032] In step 308, the reinforcing component is connected to the first part of the heated press (e.g., Figure 2the reinforcing component has a lapping surface. In step 310, the uncured panel component is engaged with an opposing second portion of the press (e.g., element 208 in Figure 2 the reinforcing component has a lapping surface. In step 310, the uncured panel component is engaged with an opposing second portion of the press (e.g., element 208 in

[0033] In step 314, suction is applied to the press to remove any air or volatiles trapped in the uncured panel component. In step 316, the press is actuated to direct the first and second portions of the press against one another such that the lapping surfaces of the reinforcing component and the panel component are complementarily engaged under pressure. In step 318, the first and second portions of the press are heated to a cure temperature associated with the panel component to thereby co-bond the lapping surfaces of the reinforcing component and the panel component together at substantially the same time, cure the panel component, and form a reinforced panel.

[0034] Figure 4 Another method of forming a reinforcing component is provided in FIG. 4, generally designated by reference numeral 400. The reinforcing component is a panel such as shown in Figure 1 The method 400 is performed using an apparatus such as shown in Figure 2 The method 400 is performed using an apparatus such as shown in

[0035] In a first step 402, a first component formed of a consolidated material having a lapping surface is positioned on a first side of a heated press. In a second step 404, a second component formed of a non-consolidated material having a lapping surface complementarily configured relative to the lapping surface of the consolidated material is positioned on an opposing second side of the heated press. In a third step 406, the lapping surface of the consolidated material is treated such that the lapping surface is active to co-bond with the non-consolidated material. In a fourth step 408, the press is actuated to direct the first and second sides of the press against one another such that the lapping surfaces of the consolidated material and the non-consolidated material are complementarily engaged under pressure. In a fifth step 410, the first and second sides of the press are heated to a cure temperature associated with the non-consolidated material to thereby co-bond the lapping surfaces of the consolidated material and the non-consolidated material together at substantially the same time, cure the non-consolidated material, and form a reinforced component.

[0036] In some examples, actuating the press to direct the first and second sides of the press against one another includes applying a pressure of about 50 to about 150 pounds per square inch (psi) to the consolidated material and the non-consolidated material between the first and second sides of the press.

[0037] In some further examples, heating the first side and the second side of the press to a cure temperature includes heating the first side and the second side of the press to about 250°F to about 500°F for about 25 minutes to about 50 minutes to substantially simultaneously co-bond the overlapping faces of the consolidated material and the non-consolidated material together, cure the non-consolidated material, and form the reinforced fastener.

[0038] Those of ordinary skill in the art of the present disclosure, having the benefit of the teachings of the present disclosure as set forth herein, appreciate that variations and further examples of the present disclosure are possible and contemplated. Accordingly, it is submitted that the present disclosure is not limited to the specific examples disclosed, and that variations and further examples are intended to be included within the scope of the appended claims. Moreover, although examples are described in the context of specific example combinations of elements and / or functions, it is recognized that different combinations of elements and / or functions are possible and contemplated. In this regard, for example, combinations of elements and / or functions other than those explicitly described are also contemplated. Although specific terminology is employed by way of examples, such terminology is only in the sense of being illustrative and not restrictive.

[0039] Item 1. A method of forming a reinforced panel, the method comprising: engaging a reinforcement component and a first portion of a heated press, the reinforcement component having an overlapping face; engaging an unconsolidated panel component with an opposing second portion of the press, the panel component having an overlapping face configured complementary to the overlapping face of the reinforcement component; treating the overlapping face of the reinforcement component such that the overlapping face is reactive to co-bond with the panel component; actuating the press to direct the first and second portions of the press against one another such that the overlapping faces of the reinforcement component and the panel component are complementary engaged under pressure; and heating the first and second portions of the press to a cure temperature associated with the panel component to substantially simultaneously co-bond the overlapping faces of the reinforcement component and the panel component together, cure the panel component, and form the reinforced panel.

[0040] Item 2. The method of item 1, wherein the reinforcement component comprises a thermoplastic or thermoset reinforcement and the panel component comprises a thermoset skin, and wherein heating the first and second portions of the press to a cure temperature comprises heating the first and second portions of the press to a cure temperature associated with the thermoset skin to substantially simultaneously co-bond the overlapping faces of the thermoplastic or thermoset reinforcement and the thermoset skin together, cure the thermoset skin, and form the reinforced panel.

[0041] Item 3. The method of item 1 or 2, wherein actuating the press to direct the first portion and the second portion of the press against one another includes applying a pressure of about 50 to about 150 pounds per square inch (psi) to the reinforcement component and the panel component between the first portion and the second portion of the press.

[0042] Item 4. The method of any one of items 1-3, wherein heating the first portion and the second portion of the press to a cure temperature includes heating the first portion and the second portion of the press to about 250 °F to about 500 °F for about 25 minutes to about 50 minutes to substantially simultaneously co-bond the overlap faces of the reinforcement component and the panel component together, cure the panel component, and form the reinforced panel.

[0043] Item 5. The method of any one of items 1-4, wherein the reinforcement component is a thermoplastic reinforcement, and wherein treating the overlap face of the thermoplastic reinforcement includes applying a thermoplastic film over the overlap face of the thermoplastic reinforcement such that the overlap face is reactive for co-bonding with the panel component.

[0044] Item 6. The method of item 5, wherein applying a thermoplastic film over the overlap face of the thermoplastic reinforcement includes applying a polyetherimide (PEI) film, a polyphenylene sulfide, a polyimide, a polyamide, a polyamide-imide, a polyester, a polybutadiene, a polyurethane, a polypropylene, a polysulfone, a polyethersulfone, a polyphenylsulfone, a polyacrylamide, a polyketone, a polyphthalamide, a polyphenylene ether, a polybutylene terephthalate, a polyethylene, a polyethylene terephthalate, a polyester-polyarylate, a polytetrafluoroethylene (PTFE), or any combination.

[0045] Item 7. The method of any one of items 1-6, wherein the reinforcement component is a thermoset reinforcement, and wherein treating the overlap face of the reinforcement component includes one or both of applying an adhesion promoter over the overlap face of the thermoset reinforcement and performing an aggressive surface treatment over the overlap face of the thermoset reinforcement such that the overlap face is reactive for co-bonding with the panel component.

[0046] Item 8. The method of item 7, wherein performing an aggressive surface treatment over the overlap face of the thermoset reinforcement includes performing a corona treatment, a plasma treatment, or a flame treatment over the overlap face of the thermoset reinforcement such that the overlap face is reactive for co-bonding with the panel component.

[0047] Item 9. The method of any one of items 1-8, further comprising applying suction to the press to remove any air or volatiles trapped in the uncured panel component.

[0048] Item 10. The method of any one of items 1-9, further comprising pre-heating the press to a pre-heated temperature, the pre-heated temperature being lower than a cure temperature associated with the panel component.

[0049] Item 11. The method of any of items 1-10, wherein engaging the reinforcement component with the first portion of the heated press comprises engaging a pressing surface of the reinforcement component with a pressing member that is complementarily configured to the opposing pressing surface, the pressing surface being opposite the lapping surface of the reinforcement component.

[0050] Item 12. The method of any of items 1-11, wherein heating the first portion and the second portion of the press to a cure temperature associated with the panel component comprises heating the first portion and the second portion of the press to a cure temperature associated with the panel component that is lower than a cure temperature associated with the reinforcement component.

[0051] Item 13. The method of any of items 1-12, wherein engaging the reinforcement component with the first portion of the heated press comprises engaging the reinforcement component having a cross-section shaped as a "bell," a "hat," an "I," a "J," or a "T" with the first portion of the heated press.

[0052] Item 14. The method of any of items 1-13, further comprising shaping or stamping the material to form the reinforcement component prior to engaging the formed reinforcement component with the first portion of the heated press.

[0053] Item 15. The method of any of items 1-14, further comprising conditioning the uncured panel layers of the panel component prior to engaging at least one of the panel layers with the second portion of the press.

[0054] Item 16. A method of forming a reinforcement component, the method comprising: positioning a first component formed of a consolidated material on a first side of a heated press, the consolidated material having a lapping surface; positioning a second component formed of a non-consolidated material on an opposing second side of the heated press, the non-consolidated material having a lapping surface that is complementarily configured relative to the lapping surface of the consolidated material; treating the lapping surface of the consolidated material such that the lapping surface is active to co-bond with the non-consolidated material; actuating the press to direct the first side and the second side of the press relative to one another such that the lapping surfaces of the consolidated material and the non-consolidated material complementarily engage under pressure; and heating the first side and the second side of the press to a cure temperature associated with the non-consolidated material to co-bond the lapping surfaces of the consolidated material and the non-consolidated material together substantially simultaneously, cure the non-consolidated material, and form the reinforcement component.

[0055] Item 17. The method of item 16, wherein actuating the press to direct the first side and the second side of the press relative to one another comprises applying a pressure of about 50 to about 150 pounds per square inch (psi) to the consolidated material and the non-consolidated material between the first side and the second side of the press.

[0056] Item 18. The method of item 16 or 17, wherein heating the first side and the second side of the press to the cure temperature comprises heating the first side and the second side of the press to about 250°F to about 500°F for about 25 minutes to about 50 minutes to substantially simultaneously co-bond the overlap faces of the consolidated material and the non-consolidated material together, cure the non-consolidated material, and form the reinforced component.

[0057] Item 19. The method of any one of items 16-18, wherein the non-consolidated material comprises a thermoplastic or thermoset reinforcement and the consolidated material comprises a thermoset skin, and wherein heating the first side and the second side of the press to the cure temperature comprises heating the first side and the second side of the press to a cure temperature associated with the thermoset skin to substantially simultaneously co-bond the overlap faces of the thermoplastic or thermoset reinforcement and the thermoset skin together, cure the thermoset skin, and form the reinforced panel.

[0058] Item 20. The method of any one of items 16-19, wherein the non-consolidated material is a thermoplastic reinforcement, and wherein treating the overlap faces of the thermoplastic reinforcement comprises applying a thermoplastic film over the overlap faces of the thermoplastic reinforcement such that the overlap faces are active to co-bond with the panel component.

[0059] Item 21. The method of item 20, wherein applying a thermoplastic film over the overlap faces of the thermoplastic reinforcement comprises applying a polyetherimide (PEI) film, a polyphenylene sulfide, a polyimide, a polyamide, a polyamide-imide, a polyester, a polybutadiene, a polyurethane, a polypropylene, a polysulfone, a polyethersulfone, a polyphenylsulfone, a polyacrylamide, a polyketone, a polyphthalamide, a polyphenylene ether, a polybutylene terephthalate, a polyethylene, a polyethylene terephthalate, a polyester-polyarylate, a polytetrafluoroethylene (PTFE), or any combination.

[0060] Item 22. The method of any one of items 16-21, wherein the non-consolidated material is a thermoset reinforcement, and wherein treating the overlap faces of the non-consolidated material comprises one or both of applying an adhesion promoter film over the overlap faces of the thermoset reinforcement and performing an aggressive surface treatment on the overlap faces of the thermoset reinforcement such that the overlap faces are active to co-bond with the consolidated material.

[0061] Item 23. The method of item 22, wherein performing an aggressive surface treatment on the overlap faces of the thermoset reinforcement comprises performing a corona treatment, a plasma treatment, or a flame treatment on the overlap faces of the thermoset reinforcement such that the overlap faces are active to co-bond with the consolidated material.

[0062] Item 24. The method of any one of items 16-23, further comprising applying suction to the press to remove any air or volatiles trapped in the unconsolidated consolidated material.

[0063] Item 25. The method of any of items 16-24, further comprising pre-heating the press to a pre-heated temperature, the pre-heated temperature being lower than a cure temperature associated with the consolidating material.

[0064] Item 26. An apparatus for forming a reinforced panel, the apparatus comprising: a first planar platen having a planar surface; a second planar platen having a planar surface adapted to engage a panel component, the second planar platen being cooperable with the first planar platen to apply pressure therebetween; and an intermediate insert adapted to engage a reinforcement component, the intermediate insert having a planar first surface cooperable with the planar surface of the first or second planar platen and an opposing second surface cooperable with and conformal to the reinforcement component such that pressure applied to the reinforcement component and the panel component between the first and second planar platens is uniformly distributed across the reinforcement component, wherein at least the intermediate insert and the first or second planar platen are heated.

[0065] Item 27. The apparatus of item 26, further comprising a heating element associated with at least the intermediate insert and the first or second planar platen, the heating element being disposed to heat at least the intermediate insert and the first or second planar platen to co-bond and cure the reinforcement component and the panel component substantially simultaneously, cure the panel component, and form the reinforced panel.

[0066] Item 28. The apparatus of item 26 or 27, wherein the reinforcement component comprises a thermoplastic or thermoset reinforcement and the panel component comprises a thermoset skin.

[0067] Item 29. The apparatus of any of items 26-28, wherein the reinforcement component is a thermoplastic reinforcement.

[0068] Item 30. The apparatus of any of items 26-29, wherein the reinforcement component is a thermoset reinforcement.

Claims

1. A method for forming a reinforcing panel, the method comprising: The press is preheated to a preheating temperature, which is lower than the curing temperature associated with the uncured panel components; The reinforcing member is joined to the heated first part of the press, the reinforcing member having an overlapping surface; The uncured panel component is joined to the opposite second part of the press, the panel component having an overlapping surface that is complementary to the overlapping surface of the reinforcing member; The overlapping surfaces of the reinforcing member are processed to make them active so that they can be bonded together with the panel member; The press is actuated to guide the first and second parts of the press relative to each other, such that the overlapping surfaces of the reinforcing member and the panel member complementarily engage under pressure; as well as The first and second parts of the press are heated to a curing temperature associated with the panel component, thereby simultaneously bonding the overlapping surfaces of the reinforcing member and the panel component together, curing the panel component, and forming the reinforced panel. Furthermore, the method also includes: The intermediate insert is engaged with the reinforcing member, wherein the intermediate insert is adapted to engage the reinforcing member, the intermediate insert having a first surface capable of engaging with a planar surface of a first or second planar platen of the press and an opposing second surface capable of engaging with and conforming to the reinforcing member such that the pressure applied to the reinforcing member and the panel member between the first and second planar platens is uniformly distributed across the reinforcing member.

2. The method according to claim 1, wherein, The reinforcing member includes a thermoplastic or thermosetting reinforcing member and the panel member includes a thermosetting skin, wherein heating the first and second portions of the press to the curing temperature includes heating the first and second portions of the press to a curing temperature associated with the thermosetting skin to simultaneously bond the overlapping surfaces of the thermoplastic or thermosetting reinforcing member and the thermosetting skin together, curing the thermosetting skin, and forming the reinforced panel.

3. The method according to claim 1, wherein, Actuating the press to guide the first and second sections of the press relative to each other includes applying a pressure of 50 to 150 psi to the space between the first and second sections of the press, as well as the panel component.

4. The method according to claim 1, wherein, Heating the first and second parts of the press to the curing temperature includes heating the first and second parts of the press to 250°F to 500°F for 25 to 50 minutes to simultaneously bond the overlapping surfaces of the reinforcing member and the panel member together, curing the panel member, and forming the reinforced panel.

5. The method according to claim 1, wherein, The reinforcing member is a thermoplastic reinforcing member, and the overlapping surface of the thermoplastic reinforcing member is processed by applying a thermoplastic film to the overlapping surface of the thermoplastic reinforcing member to make the overlapping surface active for co-bonding with the panel member.

6. The method according to claim 5, wherein, Applying the thermoplastic film to the overlapping surface of the thermoplastic reinforcement includes applying a polyetherimide (PEI) film, polyphenylene sulfide, polyimide, polyamide, polyamide-imide, polyester, polybutadiene, polyurethane, polypropylene, polysulfone, polyethersulfone, polyphenylene sulfone, polyacrylamide, polyketone, polyphthalamide, polyphenylene sulfone, polybutylene terephthalate, polyethylene, polyethylene terephthalate, polyester-polyarylate, polytetrafluoroethylene (PTFE), or any combination thereof to the overlapping surface of the thermoplastic reinforcement.

7. The method according to claim 1, wherein, The reinforcing member is a thermosetting reinforcing member, and wherein processing the overlapping surface of the reinforcing member includes one or both of applying an adhesive enhancer film to the overlapping surface of the thermosetting reinforcing member and performing an active surface treatment on the overlapping surface of the thermosetting reinforcing member to make the overlapping surface active for co-bonding with the panel member.

8. The method according to claim 7, wherein, Performing active surface treatments on the overlapping surfaces of the thermosetting reinforcement includes performing corona treatment, plasma treatment, or flame treatment on the overlapping surfaces of the thermosetting reinforcement to make the overlapping surfaces active for co-bonding with the panel component.

9. The method of claim 1, further comprising applying suction to the press to remove any air or volatiles trapped in the uncured panel component.

10. The method according to claim 1, wherein, Engaging the reinforcing member to the heated first part of the press includes engaging the pressing surface of the reinforcing member with a pressing member configured complementary to the pressing surface, the pressing surface being opposite the overlapping surface of the reinforcing member.

11. The method according to claim 1, wherein, Heating the first and second portions of the press to a curing temperature associated with the panel component includes heating the first and second portions of the press to a curing temperature associated with the panel component, which is lower than the curing temperature associated with the reinforcing component.

12. The method according to claim 1, wherein, Joining the reinforcing member to the heated first part of the press includes joining the reinforcing member having a cross-section shaped as a "bell", "hat", "I", "J", or "T" to the heated first part of the press.

13. The method of claim 1, further comprising forming or stamping the material to form the reinforcing member before joining the formed reinforcing member to the heated first portion of the press.

14. The method according to any one of claims 1-13, further comprising finishing the uncured layers of the panel component before joining at least one of the layers to the second part of the press.

15. A method of forming a reinforcing member, the method comprising: The press is preheated to a preheating temperature, which is lower than the curing temperature associated with the uncured second component; A first component formed of a consolidating material is positioned on a first side of the heated press, the consolidating material having an overlapping surface; A second component formed of an unconsolidated material is positioned on the opposite second side of the heated press, the unconsolidated material having an overlapping surface that is complementary to the overlapping surface of the consolidated material; The overlapping surfaces of the consolidated material are treated to make them active so that they can be bonded together with the unconsolidated material. The press is actuated to guide the first and second sides of the press relative to each other, such that the overlapping surfaces of the bonded material and the unbonded material are complementaryly joined under pressure; as well as The first and second sides of the press are heated to a curing temperature associated with the unbonded material to simultaneously bond the overlapping surfaces of the bonded and unbonded materials together, cure the unbonded material, and form the reinforcing member. Furthermore, the intermediate insert is adapted to engage the reinforcing member, the intermediate insert having a first planar surface capable of engaging with the planar surface of the first or second planar platen of the press and an opposing second surface capable of engaging with and conforming to the reinforcing member, such that the pressure applied to the reinforcing member and the panel member between the first and second planar platens is uniformly distributed across the reinforcing member.

16. The method according to claim 15, wherein, Actuating the press to guide the first and second sides of the press relative to each other includes applying a pressure of 50 to 150 psi to the bonded material and the unbonded material between the first and second sides of the press.

17. The method according to claim 15 or 16, wherein, Heating the first and second sides of the press to the curing temperature includes heating the first and second sides of the press to 250°F to 500°F for 25 to 50 minutes to simultaneously bond the overlapping surfaces of the bonded material and the unbonded material together, curing the unbonded material, and forming the reinforcing member.

18. An apparatus for forming a reinforced panel, the apparatus comprising: The first planar platform has a planar surface; The second planar platform has a planar surface suitable for engaging panel components, and the second planar platform can operate in conjunction with the first planar platform to apply pressure therebetween; as well as An intermediate insert, adapted to engage a reinforcing member, the intermediate insert having a first planar surface capable of engaging with a planar surface of the first or second planar platform and an opposing second surface capable of engaging with and conforming to the reinforcing member, such that pressure applied to the reinforcing member and the panel member between the first and second planar platforms is uniformly distributed across the reinforcing member. In this process, at least the intermediate insert and the first or second planar platform are heated, and The first and second planar panels are preheated to a preheating temperature lower than the curing temperature associated with the uncured panel components.

19. The apparatus of claim 18, further comprising a heating element associated with at least the intermediate insert and the first planar platform or the second planar platform, the heating element being configured to heat at least the intermediate insert and the first planar platform or the second planar platform to simultaneously bond and cure the reinforcing member and the panel member, curing the panel member and forming a reinforced panel.

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