Composite layered assembly and method of forming the same

Abstract

The present disclosure relates to composite layered assemblies and methods of forming the same. A system and method of forming a composite layered assembly (300) includes disposing a first glass fiber layer (304) between a non-woven carbon fiber layer (302) and a decorative layer (306). The decorative layer (306), the first glass fiber layer (304), and the non-woven carbon fiber layer (302) are exposed to one or more curing conditions to form the composite layered assembly (300).

Description

Technical Field

[0001] Examples of this disclosure generally relate to systems and methods for forming composite layered assemblies comprising nonwoven carbon fiber materials and glass fiber materials, which may be used on or within aircraft. Background Technology

[0002] Traditionally, cargo liners used to line the surfaces within the cargo compartment of an aircraft are made of fiberglass coated with phenolic or cyanate ester resins and cured together with a decorative film (such as Tedlar). Depending on the loads being moved in and out of the cargo compartment, the cargo liners may experience excessive wear and tear. After enduring a certain degree of wear, the liners may require repair or replacement.

[0003] Furthermore, cargo linings are designed to meet certain oil combustion requirements or other flammability requirements. However, while fiberglass materials can meet some flammability requirements, they are still flammable. It is understandable that there is a need for improved linings made of non-flammable materials, with improved durability and the ability to withstand higher levels of abrasion. Summary of the Invention

[0004] There is a need for liners that can be installed inside aircraft (e.g., in the cargo section of an aircraft). Liners can be made of layers of various materials, which can be semi-rigid, non-flammable, and have improved durability and / or the ability to withstand high levels of abrasion. In view of these needs, certain examples of this disclosure provide a system and method comprising distributing a first glass fiber layer between a nonwoven carbon fiber layer and a decorative layer. The decorative layer, the first glass fiber layer, and the nonwoven carbon fiber layer are exposed to one or more curing conditions to form a composite layered assembly.

[0005] In one example, exposing the decorative layer, the first glass fiber layer, or the nonwoven carbon fiber layer to curing conditions alters one or more properties of one or more of the decorative layer, the first glass fiber layer, or the nonwoven carbon fiber layer.

[0006] In another example, the method includes: distributing a second glass fiber layer relative to a nonwoven carbon fiber layer; and exposing the decorative layer, the first glass fiber layer, the nonwoven carbon fiber layer, and the second glass fiber layer to one or more curing conditions to form a composite layered assembly.

[0007] In one example, the method may include applying heat and / or pressure to one or more nonwoven carbon fiber components to form a nonwoven carbon fiber layer. Optionally, the nonwoven carbon fiber component may be made of recycled nonwoven carbon fiber material. Optionally, the first glass fiber layer may be made of a thermoplastic polymer or other material, and the first glass fiber layer may be arranged relative to the one or more nonwoven carbon fiber components. Heat and / or pressure may be applied to the first glass fiber layer and the one or more nonwoven carbon fiber components to form a sub-assembly including the nonwoven carbon fiber layer and the first glass fiber layer.

[0008] In one example, the first glass fiber layer may be made of a thermosetting glass fiber composite or a thermoplastic glass fiber composite. Optionally, the first glass fiber layer may be impregnated with a resin product.

[0009] In one example, the composite layered component can be machined to form a layered product, and the layered product can be installed within an aircraft system.

[0010] Certain examples of this disclosure provide a composite layered assembly comprising: a nonwoven carbon fiber layer; a first glass fiber layer having a bottom surface operatively bonded to a top surface of the nonwoven carbon fiber layer; and a decorative layer operatively bondable to the top surface of the first glass fiber layer. The decorative layer, the first glass fiber layer, and the nonwoven carbon fiber layer are exposed to one or more curing conditions to form the composite layered assembly.

[0011] This disclosure provides an example of a method for forming a composite layered assembly, the method comprising: arranging a bottom surface of a first glass fiber layer facing a top surface of a recycled carbon fiber layer made of a nonwoven carbon fiber material; arranging a top surface of a second glass fiber layer facing the bottom surface of the recycled carbon fiber layer; and arranging a decorative layer relative to the top surface of the first glass fiber layer. The decorative layer, the first glass fiber layer, the recycled carbon fiber layer, and the second glass fiber layer are exposed to one or more curing conditions to form the composite layered assembly. Attached Figure Description

[0012] Figure 1 A perspective view is shown of a manufacturing operation for forming a nonwoven carbon fiber layer according to an example of this disclosure.

[0013] Figure 2 A nonwoven carbon fiber layer according to an example of this disclosure is shown.

[0014] Figure 3 An exploded perspective view of a composite layered component according to an example of this disclosure is shown.

[0015] Figure 4An exploded perspective view of a composite layered component according to an example of this disclosure is shown.

[0016] Figure 5 An exploded perspective view of a composite layered component according to an example of this disclosure is shown.

[0017] Figure 6 A flowchart illustrating a method for forming a composite layered component according to an example of this disclosure is shown.

[0018] Figure 7 A frontal perspective view of an aircraft system according to an example of this disclosure is shown.

[0019] Figure 8 It shows Figure 7 A perspective view of the internal components of the aircraft system shown. Detailed Implementation

[0020] The foregoing description of the invention and certain examples will be better understood when read in conjunction with the accompanying drawings. As used herein, an element or step described in the singular and preceded by the word "a" or "an" should be understood to not necessarily exclude multiple elements or steps. Furthermore, references to "an example" are not intended to be construed as excluding the existence of additional examples also incorporated into the described features. Moreover, unless expressly stated to the contrary, examples that "comprise" or "have" an element or multiple elements having a particular condition may include additional elements that do not have that condition.

[0021] As described herein, examples of this disclosure provide systems and methods for forming layered components, said layered components including one or more glass fiber layers, nonwoven carbon fiber layers, and optional decorative layers. In one example, the layered component may include a glass fiber layer located between the decorative layer and the nonwoven carbon fiber layer. In another example, the layered component may include a first glass fiber layer located between the decorative layer and the nonwoven carbon fiber layer and a second glass fiber layer located on a second side of the nonwoven carbon fiber layer. For example, the nonwoven carbon fiber layer may be located between the first glass fiber layer and the second glass fiber layer.

[0022] These layers can be exposed to one or more curing, bonding, or joining conditions to chemically and / or physically bond, join, and / or attach multiple layer components together to form a cured assembly. The cured composite layered assembly can be formed into one or more structures through one or more secondary manufacturing processes. The formed one or more structures can be coupled to or installed within systems (such as aircraft systems or other transportation systems), buildings, or other fixed structures.

[0023] In one example, the nonwoven carbon fiber layer can be formed from one or more nonwoven carbon fiber components, sheets, elements, etc. For example, one or more rolls of nonwoven carbon fiber can be exposed to pressure and / or heat to mold the nonwoven carbon fiber segments together to form a rigid nonwoven carbon fiber layer. In one example, the nonwoven carbon fiber component can be made from recycled carbon fiber material. In one example, the glass fiber layer can be made from a thermoplastic polymer or other material and can be exposed to pressure and / or heat together with the nonwoven carbon fiber to form a sub-assembly comprising the glass fiber layer and the nonwoven carbon fiber layer. In another example, the glass fiber layer can be made from a thermosetting glass fiber material or an alternative material and can be cured together with the nonwoven carbon fiber layer and a decorative layer to form a composite layered assembly.

[0024] Figure 1 A perspective view is shown of a manufacturing operation for forming a nonwoven carbon fiber layer according to an example of this disclosure. The nonwoven carbon fiber layer can be formed by stacking one or more nonwoven carbon fiber components 102A-102C together and applying heat and / or pressure, for example, by means of rolling elements 104A, 104B. For example, components 102A-102C can be in sheet, roll, etc., and each of components 102A-102C can be made of nonwoven carbon fiber material. In at least one example, one or more of components 102A-102C can be made of recycled nonwoven carbon fiber material.

[0025] Figure 2 A nonwoven carbon fiber layer 202 according to an example of the present disclosure is shown. The nonwoven carbon fiber layer 202 is formed by applying heat and / or pressure to nonwoven parts 102A-102C by rolling elements 104A-104B. In one example, the nonwoven carbon fiber layer 202 may be referred to as a carbon fiber laminate, a recycled carbon fiber laminate, a nonwoven laminate, etc.

[0026] In the example shown, the nonwoven carbon fiber layer 202 is formed by processing the components 102A-102C through a dual-belt press while exposing them to a temperature of approximately 700°F. For example, recycled nonwoven carbon fiber components can be processed through continuous or semi-continuous compression molding steps to produce a semi-flexible lining or laminate. In another example, the nonwoven components 102A-102C can be placed in a press, die, etc., and pressure and / or heat can be applied to the components to form the carbon fiber layer 202. By exposing the components to pressure and / or heat conditions, the components 102A-102C can be molded, shaped, or bonded into the nonwoven carbon fiber layer 202. For example, the components 102A-102C can be combined together to form a single, coherent, integral layer. In one example, the molded carbon fiber layer 202 may have a greater stiffness, rigidity, hardness, etc., than the nonwoven components 102A-102C. For example, during the formation of the nonwoven carbon fiber layer 202, heat and / or pressure are applied to the components 102A-102C to change one or more material properties of the components 102A-102C.

[0027] In one example, the number of nonwoven carbon fiber components 102A-102C used to form layer 202 can be determined based on the area weight of a system (e.g., an aircraft system) in which layer 202 can be used. The nonwoven carbon fiber layer 202 can be formed from a single nonwoven component, two nonwoven components, or more than two nonwoven components. As another example, the number of nonwoven carbon fiber components 102A-102C used to form layer 202 can be based on the availability of one or more different weights, thicknesses, dimensions, etc., of the components.

[0028] In one or more examples, the materials and / or products used in each layer of the composite layered component 300 may be based on one or more requirements of the structure formed by the composite layered component (e.g., durability requirements, weight requirements, thickness requirements, thermal requirements, material toxicity requirements, flammability requirements, aesthetic requirements, etc.).

[0029] Figure 3 An exploded perspective view of a composite layered assembly 300 according to an example of the present disclosure is shown. The composite layered assembly 300 includes a nonwoven carbon fiber layer 302 formed from a nonwoven carbon fiber component 102A. The composite layered assembly also includes a first glass fiber layer 304 and a decorative layer 306, wherein the first glass fiber layer 304 is disposed between the decorative layer 306 and the nonwoven carbon fiber layer 302. For example, the bottom surface 314 of the first glass fiber layer 304 faces and is coupled to the top surface 312 of the nonwoven carbon fiber layer 302; and the top surface 316 of the first glass fiber layer 304 faces and is coupled to the bottom surface 318 of the decorative layer 306.

[0030] In one example, the first glass fiber layer 304 may be a glass fiber material that can be coated with a thermoplastic polymer coating. Alternatively, the thermoplastic-coated glass fiber material may be impregnated with a resin product. In another example, the first glass fiber layer 304 may be a thermosetting glass fiber material that can be impregnated with a resin product.

[0031] Decorative layer 306 may include one or more features (e.g., color, pattern, graphic, texture elements such as bumps or recesses) disposed on the top surface 320 of decorative layer 306. One or more features may be based on the final installation location in which the composite layer assembly 300 may be placed.

[0032] The decorative layer 306, the first glass fiber layer 304, and the nonwoven carbon fiber layer 302 can be exposed to one or more curing conditions to form a cured and assembled composite layered assembly 300. For example, exposing the layered assembly to curing conditions can physically and / or chemically bond, cure, connect, etc., the layers of the component together, thereby altering one or more properties of one or more layers.

[0033] In one example, layers 302, 304, and 306 may be arranged, stacked, and / or positioned together, and may be placed within a curing apparatus that exposes the layered material to one or more adhesive, bonding, and / or curing conditions (e.g., temperature, humidity, pressure, etc.). As an example, a cured composite layered assembly 300 can be formed by placing layers 302, 304, and 306 in a metal mold, metal mold assembly, autoclave, oven, etc., and exposing the layers to one or more curing conditions. As another example, a cured composite layered assembly 300 can be formed by placing layers 302, 304, and 306 in a vacuum bag and exposing the layers to one or more of temperature, pressure, and / or humidity conditions to form a cured material assembly.

[0034] In one or more examples, decorative layer 306 may include an adhesive layer or one or more adhesive elements (not shown) operatively bonded to the bottom surface 318 of decorative layer 306. For example, the adhesive layer or adhesive element may be a pressure-sensitive adhesive, adhesive liner, adhesive paste, etc., which may be used to bond the bottom surface 318 of decorative layer 306 to the top surface 316 of first glass fiber layer 304, for example, during the exposure of the layers to curing conditions.

[0035] In one example, the first glass fiber layer 304 may be made of a thermoplastic-coated glass fiber material, and the first glass fiber layer 304 may be molded together with the nonwoven carbon fiber layer 302 during a compression molding stage. For example, the first glass fiber layer 304 may be combined with the nonwoven carbon fiber component 102 (such as...). Figure 1 As shown, the first glass fiber layer 304 and component 102 are arranged together such that they are processed together by rolling elements 104A-104B to form a sub-assembly including the first glass fiber layer 304 and the nonwoven carbon fiber layer 202. After the first glass fiber layer 304 and the nonwoven carbon fiber layer 202 are molded together, a decorative layer 306 can be positioned on the top surface 316 of the first glass fiber layer 304, and the three layers can be exposed to curing conditions to form a composite layered assembly 300.

[0036] In one example, the curing conditions can vary based on whether the first glass fiber layer 304 is molded together with the nonwoven carbon fiber components 102A-102C during the compression molding step. For example, if the first glass fiber layer 304 is not molded together with the nonwoven carbon fiber layer 202, these layers can undergo a first set of curing conditions to form the composite layered assembly 300; or, if the first glass fiber layer 304 is molded together with the nonwoven carbon fiber layer 202, these layers can undergo a different second set of curing conditions.

[0037] Figure 4 A composite layered assembly 400 according to another example of the present disclosure is shown. The composite layered assembly 400 includes a nonwoven carbon fiber layer 402, a first glass fiber layer 304, and a decorative layer 306. In the illustrated example, the nonwoven carbon fiber layer 402 may be formed from two nonwoven components 102A, 102B. For example, these two nonwoven components 102A, 102B may be processed by rolling elements 104A, 104B to form a molded nonwoven carbon fiber layer 402.

[0038] These layers are arranged such that the first glass fiber layer 304 is positioned between the decorative layer 306 and the nonwoven carbon fiber layer 402. For example, the bottom surface 318 of the decorative layer 306 faces the top surface 316 of the first glass fiber layer 304, and the bottom surface 314 of the first glass fiber layer 304 faces the top surface 412 of the nonwoven carbon fiber layer 402.

[0039] The nonwoven carbon fiber layer 402, the first glass fiber layer 304, and the decorative layer 306 can be exposed to one or more curing conditions to form a cured and assembled composite layered assembly 400. For example, exposing the layered assembly to curing conditions can physically and / or chemically bond, cure, connect, etc., the layers of the component together, thereby altering one or more properties of one or more layers.

[0040] Figure 5A composite layered assembly 500 according to another example of this disclosure is shown. The composite layered assembly 500 includes a nonwoven carbon fiber layer 402 (which has been formed from two nonwoven carbon fiber components 102A, 102B), a first glass fiber layer 304, and a decorative layer 306. The composite layered assembly 500 also includes a second glass fiber layer 508 disposed on the bottom surface 410 of the nonwoven carbon fiber layer 402. For example, the top surface 524 of the second glass fiber layer 508 faces and is coupled to the bottom surface 410 of the nonwoven carbon fiber layer 402.

[0041] In one example, the first glass fiber layer 304 and the second glass fiber layer 508 can be made of the same or similar materials. As an example, the first and second glass fiber layers can be made of a glass fiber material that can be coated with a thermoplastic polymer coating. Optionally, the thermoplastic-coated glass fiber material can be impregnated with a resin product. In another example, the first glass fiber layer 304 and the second glass fiber layer 508 can be made of a thermosetting glass fiber material that can be impregnated with a resin product. Optionally, the first glass fiber layer 304 and the second glass fiber layer 508 can be made of alternative composite materials.

[0042] Decorative layer 306, first glass fiber layer 304, nonwoven carbon fiber layer 402, and second glass fiber layer 508 can be exposed to one or more curing conditions to form a cured and assembled composite layered assembly 500. For example, exposing the layered assembly to curing conditions can physically and / or chemically bond, cure, connect, etc., the layers of the component together, thereby altering one or more properties of one or more layers.

[0043] In one example, the first glass fiber layer 304 and the second glass fiber layer 508 may be made of a thermoplastic-coated glass fiber material, and the first glass fiber layer 304 and the second glass fiber layer 508 may be molded together with the nonwoven carbon fiber layer 402 during a compression molding stage. For example, nonwoven carbon fiber components 102A and 102B may be arranged between the first glass fiber layer 304 and the second glass fiber layer 508, and then the first glass fiber layer 304, the second glass fiber layer 508, and components 102A and 102B are processed together by rolling elements 104A and 104B to form a sub-assembly including the first glass fiber layer 304, the second glass fiber layer 508, and the nonwoven carbon fiber layer 202. After the first glass fiber layer 304 and the second glass fiber layer 508 are molded together with the nonwoven carbon fiber layer 202, a decorative layer 306 may be positioned on the top surface 316 of the first glass fiber layer 304, and these four layers may be exposed to curing conditions to form a composite layered assembly 500.

[0044] Figure 6A flowchart 600 illustrates a method for forming a composite layered assembly according to an example of this disclosure. At 602, the number of glass fiber layers to be included in the composite layered assembly is selected. The number of glass fiber layers may be based on one or more requirements of the structure to be formed from the composite layered assembly (e.g., durability requirements, weight requirements, thickness requirements, thermal requirements, material toxicity requirements, flammability requirements, aesthetic requirements, etc.). The composite layered assembly may include one glass fiber layer (e.g., in...). Figure 3 (as shown in the diagram), or two glass fiber layers (e.g., in...). Figure 5 (as shown in the figure), or more than two glass fiber layers (not shown).

[0045] At 604, it is determined whether the glass fiber layer is made of a thermoplastic polymer or other similar material. For example, if the glass fiber layer is made of a thermoplastic polymer, it can be molded together with the nonwoven carbon fiber component. Alternatively, if the glass fiber layer is made of another material (e.g., a thermosetting material), it may not be molded together with the nonwoven carbon fiber component. If the glass fiber layer is made of a thermoplastic material, the process proceeds to 606.

[0046] At 606, one or more nonwoven carbon fiber components (e.g., sheets, rolls, etc.) are positioned relative to the glass fiber layer. If a glass fiber layer is selected at 602, it can be disposed on one surface of one of the nonwoven components. If two glass fiber layers are selected at 602, the nonwoven carbon fiber component can be positioned between the two glass fiber layers. At 608, heat and / or pressure are applied to the nonwoven carbon fiber component and the glass fiber layer to mold the sub-assembly comprising the nonwoven carbon fiber layer and the glass fiber layer together. In one or more examples, exposing the glass fiber layer and carbon fiber component to heat and / or pressure conditions can alter one or more properties of the glass fiber layer and / or carbon fiber component, such as stiffness, elasticity, tensile strength, toughness, ductility, one or more chemical properties, etc.

[0047] At 610, a decorative layer is positioned on the top surface of one of the glass fiber layers, such that the glass fiber layer is positioned between the nonwoven carbon fiber layer and the decorative layer. At 616, the decorative layer, the glass fiber layer, and the nonwoven carbon fiber layer are exposed to one or more curing conditions to cure or bond these layers together to form a composite layered assembly.

[0048] Returning to step 604, if the glass fiber layer is not made of a thermoplastic polymer material, the process proceeds to 612. At 612, heat and / or pressure are applied to one or more nonwoven carbon fiber components to mold these components together to form a molded rigid nonwoven carbon fiber layer. In one or more examples, exposing the carbon fiber components to heat and / or pressure conditions can alter one or more properties of the carbon fiber components, such as stiffness, elasticity, tensile strength, toughness, ductility, one or more chemical properties, etc.

[0049] At 614, the nonwoven carbon fiber layer is arranged together with the glass fiber layer and the decorative layer, such that at least one glass fiber layer is positioned between the decorative layer and the nonwoven carbon fiber layer. At 616, the decorative layer, the glass fiber layer, and the nonwoven carbon fiber layer are exposed to one or more bonding, joining, and / or curing conditions (e.g., temperature, humidity, pressure, etc.) to form a cured composite layered assembly.

[0050] In one or more examples, the solidified composite layered component may be machined, manipulated, cut, sliced, shaped, or subjected to any alternative secondary manufacturing process to form a layered product that can be used within a system such as an aircraft system. Figure 7 A frontal perspective view of an aircraft 700 according to an example of this disclosure is shown. The aircraft 700 includes a propulsion system 712, which may include, for example, two turbofan engines 714. Optionally, the propulsion system 712 may include more engines 714 than shown. The engines 714 are carried by the wings 716 of the aircraft 700. In other examples, the engines 714 may be carried by the fuselage 718 and / or the tail 720. The tail 720 may also support a horizontal stabilizer 722 and a vertical stabilizer 724.

[0051] The fuselage 718 of the aircraft 700 defines the internal cabin, which may include internal sidewall panels, ceiling panels, and floor panels. The internal cabin may include a cockpit, one or more work sections (e.g., galley, carry-on baggage area, etc.), one or more passenger sections (e.g., first class, business class, and economy class sections), one or more storage sections (e.g., cargo section), and a rear section. Parts of the aircraft 700 (such as the ceiling panels, sidewall panels, or floor panels of the cargo section or any other section of the aircraft 700) may be formed from layered components including nonwoven carbon fiber layers as described herein.

[0052] Alternatively, instead of aircraft systems, the examples of this disclosure can be used with a variety of other fixed and / or non-fixed structures. For example, layered assemblies comprising glass fiber and nonwoven carbon fiber laminates can be used to form one or more structures for use on and / or within buildings or other vehicles such as cars, buses, locomotives and train carriages, ships, spacecraft, etc.

[0053] Figure 8 The internal parts of a vehicle (such as) are shown as examples according to this disclosure. Figure 7 The image shows a perspective view of the cargo section 800 of the aircraft 700. The cargo section 800 includes a ceiling panel 802, multiple side panels 804, and a floor panel 806 defining the interior cargo area of ​​the aircraft. In one or more examples, the cargo section 800 may include one or more liners 812, 814, 816, 818, which may be operatively attached to the ceiling panel, side panels, and / or floor panel via one or more fastening elements. Liners 812-818 may be made of a composite layered assembly (e.g., comprising one or more layers of fiberglass, nonwoven carbon fiber, and decorative layers). For example, the composite layered assembly may be machined, shaped, cut, spliced, or may undergo any alternative secondary manufacturing process to form a layered product of suitable size and shape for installation within the cargo section 800 of the aircraft, within another section of the aircraft, within another type of vehicle (e.g., a ship), within a building, or other fixed installation.

[0054] As described herein, examples of this disclosure provide systems and methods for forming composite layered assemblies comprising a nonwoven carbon fiber material, one or more glass fiber layers, and optional decorative layers. The composite layered assembly can be formed as a structure that can be coupled to or installed within an aircraft (such as within a cargo section of an aircraft). The composite layered assembly can be used to form semi-rigid, high-abrasion, non-flammable lining structures for aircraft cargo interior linings. For example, the composite layered assembly can be non-flammable, or can have improved flammability compared to layered assemblies without nonwoven carbon fiber layers, assemblies including woven carbon fiber layers, etc. Additionally, the composite layered assembly can have improved durability compared to assemblies without one or more glass fiber layers. For example, examples of this disclosure provide systems and methods for forming structures with improved flammability requirements and / or capabilities, improved durability, and improved sustainability (e.g., in response to the use of recycled nonwoven components), which, compared to known material assemblies for forming linings installed within aircraft cargo sections, offer greater opportunities for material selection to meet one or more structural requirements.

[0055] Furthermore, this disclosure includes examples pursuant to the following terms:

[0056] Clause 1: A method comprising:

[0057] The first glass fiber layer is arranged between the nonwoven carbon fiber layer and the decorative layer; and

[0058] The decorative layer, the first glass fiber layer, and the nonwoven carbon fiber layer are exposed to one or more curing conditions to form a composite layered assembly.

[0059] Clause 2: The method according to Clause 1, wherein exposing the decorative layer, the first glass fiber layer and the nonwoven carbon fiber layer to the one or more curing conditions alters one or more properties of the first glass fiber layer, the nonwoven carbon fiber layer or the decorative layer.

[0060] Clause 3: The method described according to Clause 1 or 2 further includes:

[0061] A second glass fiber layer is arranged relative to the nonwoven carbon fiber layer; and

[0062] The decorative layer, the first glass fiber layer, the nonwoven carbon fiber layer, and the second glass fiber layer are exposed to one or more curing conditions to form the composite layered assembly.

[0063] Clause 4: The method according to any one of Clauses 1-3, the method further includes:

[0064] Apply one or more of heat or pressure to one or more nonwoven carbon fiber components to form the nonwoven carbon fiber layer.

[0065] Clause 5: The method according to Clause 4, wherein the one or more nonwoven carbon fiber components are made of recycled nonwoven carbon fiber material.

[0066] Clause 6: The method according to Clause 4, wherein the first glass fiber layer is made of a thermoplastic material, and the method further comprises:

[0067] The first glass fiber layer is arranged relative to the one or more nonwoven carbon fiber components; and

[0068] One or more of heat or pressure are applied to the one or more nonwoven carbon fiber components and the first glass fiber layer to form a sub-assembly including the nonwoven carbon fiber layer and the first glass fiber layer.

[0069] Clause 7: The method according to any one of Clauses 1-6, wherein the first glass fiber layer is made of either a thermosetting glass fiber composite material or a thermoplastic glass fiber composite material.

[0070] Clause 8: The method according to any one of Clauses 1-7, wherein the first glass fiber layer is configured to be impregnated with a resin product.

[0071] Clause 9: The method according to any one of Clauses 1-8, the method further includes:

[0072] The composite layered component is machined to form a layered product; and

[0073] The layered product is installed within the aircraft system.

[0074] Clause 10: A composite layered component, said composite layered component comprising:

[0075] Nonwoven carbon fiber layer;

[0076] A first glass fiber layer having a bottom surface configured to be operatively coupled to a top surface of the nonwoven carbon fiber layer; and

[0077] A decorative layer, configured to be operatively bonded to the top surface of the first fiberglass layer.

[0078] The decorative layer, the first glass fiber layer, and the nonwoven carbon fiber layer are configured to be exposed to one or more curing conditions to form the composite layered assembly.

[0079] Clause 11: The composite layered assembly according to Clause 10 further includes a second glass fiber layer configured to be operatively coupled to the bottom surface of the nonwoven carbon fiber layer.

[0080] The decorative layer, the first glass fiber layer, the nonwoven carbon fiber layer, and the second glass fiber layer are configured to be exposed to one or more curing conditions to form the composite layered assembly.

[0081] Clause 12: The composite layered assembly according to Clause 11, wherein the first glass fiber layer and the second glass fiber layer are configured to be impregnated with a resin product.

[0082] Clause 13: The composite layered assembly according to Clause 11, wherein the first glass fiber layer and the second glass fiber layer are made of either a thermosetting glass fiber composite or a thermoplastic glass fiber composite.

[0083] Clause 14: A composite layered assembly according to any one of Clauses 10-13, wherein the nonwoven carbon fiber layer is configured to be made of recycled nonwoven carbon fiber material.

[0084] Clause 15: Composite layered components according to any one of Clauses 10-14:

[0085] The first glass fiber layer is made of a thermoplastic material.

[0086] The first glass fiber layer is configured to be arranged relative to one or more nonwoven carbon fiber components, the nonwoven carbon fiber layer being configured to be formed of the one or more nonwoven carbon fiber components, and

[0087] The first glass fiber layer and the one or more nonwoven carbon fiber components are configured to be exposed to heat or pressure in one or more ways to form a sub-assembly including the nonwoven carbon fiber layer and the first glass fiber layer.

[0088] Clause 16: The composite layered assembly according to any one of Clauses 10-15 further includes an adhesive layer configured to be positioned between the top surface of the first glass fiber layer and the decorative layer to bond the decorative layer to the top surface of the first glass fiber layer during exposure to the one or more curing conditions.

[0089] Clause 17: A method for forming a composite layered component, the method comprising:

[0090] The bottom surface of a first glass fiber layer is arranged relative to the top surface of the recycled carbon fiber layer, and the recycled carbon fiber layer is configured to be made of nonwoven carbon fiber material;

[0091] The top surface of the second glass fiber layer is arranged relative to the bottom surface of the recycled carbon fiber layer;

[0092] A decorative layer is disposed on the top surface of the first fiberglass layer; and

[0093] The decorative layer, the first glass fiber layer, the recycled carbon fiber layer, and the second glass fiber layer are exposed to one or more curing conditions to form the composite layered assembly.

[0094] Clause 18: The method according to Clause 17 further comprises: applying one or more of pressure or heat to the nonwoven carbon fiber material to form the recycled carbon fiber layer.

[0095] Clause 19: The method according to Clause 18, wherein the first glass fiber layer and the second glass fiber layer are made of a thermoplastic material, and the method further comprises:

[0096] The first glass fiber layer and the second glass fiber layer are arranged relative to the nonwoven carbon fiber material; and

[0097] One or more of heat or pressure are applied to the first glass fiber layer, the second glass fiber layer, and the nonwoven carbon fiber material to form a sub-assembly comprising the recycled carbon fiber layer, the first glass fiber layer, and the second glass fiber layer.

[0098] Clause 20: The method according to any one of Clauses 17-19, said method further includes:

[0099] The composite layered component is formed into a layered product; and

[0100] The layered product is installed within the aircraft system.

[0101] As described herein, examples of this disclosure provide structures formed from composite layered components, wherein the composite layered components include one or more nonwoven carbon fiber parts and one or more glass fiber layers. The layered components can be coupled to and / or used within an aircraft. Furthermore, examples of this disclosure provide layered components with improved flammability, improved durability, and improved sustainability compared to layered components without nonwoven carbon fiber layers and / or glass fiber layers.

[0102] While various spatial and directional terms (such as top, bottom, lower, middle, horizontal, horizontal, vertical, front, etc.) may be used to describe examples of this disclosure, it should be understood that these terms are used only with respect to the orientation shown in the accompanying drawings. The orientation may be reversed, rotated, or otherwise changed such that an upper portion is a lower portion, or vice versa, a horizontal portion becomes a vertical portion, etc.

[0103] As used herein, structures, constraints, or elements “configured” to perform tasks or operations are structurally shaped, constructed, or adapted in a manner corresponding to the task or operation. For clarity and to avoid ambiguity, objects that can only be modified to perform tasks or operations are not “configured” to perform tasks or operations as used herein.

[0104] It should be understood that the above description is intended to be exemplary and not restrictive. For example, the above examples (and / or aspects thereof) may be used in combination with each other. Furthermore, many modifications may be made to adapt particular situations or materials to the teachings of the various examples of this disclosure without departing from its scope. While the dimensions and types of materials described herein are intended to define aspects of the various examples of this disclosure, these examples are by no means restrictive and are exemplary. Many other examples will be apparent to those skilled in the art upon review of the above description. Therefore, the scope of the various examples of this disclosure should be determined by reference to the appended claims and the full scope of their equivalents. In the appended claims and the detailed description herein, the terms “including” and “in which” are used as simple English equivalents to the corresponding terms “comprising” and “wherein”. Furthermore, the terms “first,” “second,” and “third,” etc., are used merely as labels and are not intended to impose numerical requirements on their objects. Moreover, the limitations of the following claims are not written in a means-plus-function format.

[0105] This written description uses examples to disclose various examples (including best practices) of this disclosure and also enables any person skilled in the art to practice the various examples of this disclosure (including making and using any device or system and performing any incorporated methods). The patentable scope of the various examples of this disclosure is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially indistinguishable from the literal language of the claims.

Claims

1. A method, the method comprising: The first glass fiber layer (304) is arranged between the nonwoven carbon fiber layer (302) and the decorative layer (306); and The decorative layer (306), the first glass fiber layer (304), and the nonwoven carbon fiber layer (302) are exposed to one or more curing conditions to form a composite layered assembly (300).

2. The method according to claim 1, wherein, Exposing the decorative layer (306), the first glass fiber layer (304), and the nonwoven carbon fiber layer (302) to one or more curing conditions alters one or more properties of one or more of the first glass fiber layer (304), the nonwoven carbon fiber layer (302), or the decorative layer (306).

3. The method according to claim 1, further comprising: A second glass fiber layer (508) is arranged relative to the nonwoven carbon fiber layer (302); and The decorative layer (306), the first glass fiber layer (304), the nonwoven carbon fiber layer (302), and the second glass fiber layer (508) are exposed to one or more curing conditions to form the composite layered assembly.

4. The method according to claim 1, further comprising: One or more of heat or pressure are applied to one or more nonwoven carbon fiber components (102A-102C) to form the nonwoven carbon fiber layer (302).

5. The method according to claim 4, wherein, The one or more nonwoven carbon fiber components (102A-102C) are made of recycled nonwoven carbon fiber material.

6. A composite layered component (300), the composite layered component (300) comprising: Nonwoven carbon fiber layer (302); A first glass fiber layer (304) having a bottom surface (314) configured to be operatively coupled to a top surface (312) of the nonwoven carbon fiber layer (302); and A decorative layer (306) is configured to be operatively bonded to the top surface (316) of the first fiberglass layer (304). The decorative layer (306), the first glass fiber layer (304), and the nonwoven carbon fiber layer (302) are configured to be exposed to one or more curing conditions to form the composite layered assembly (300).

7. The composite layered assembly according to claim 6, further comprising a second glass fiber layer (508) configured to be operatively coupled to the bottom surface (410) of the nonwoven carbon fiber layer (302), in, The decorative layer (306), the first glass fiber layer (304), the nonwoven carbon fiber layer (302), and the second glass fiber layer (508) are configured to be exposed to one or more curing conditions to form the composite layered assembly (500).

8. The composite layered component according to claim 7, wherein, The first glass fiber layer (304) and the second glass fiber layer (508) are configured to be impregnated with a resin product.

9. The composite layered component according to claim 7, wherein, The first glass fiber layer (304) and the second glass fiber layer (508) are made of either a thermosetting glass fiber composite material or a thermoplastic glass fiber composite material.

10. A method for forming a composite layered component (500), the method comprising: The bottom surface (314) of the first glass fiber layer (304) is arranged to face the top surface (412) of the recycled carbon fiber layer (402), which is configured to be made of nonwoven carbon fiber material. The top surface (524) of the second glass fiber layer (508) is arranged to face the bottom surface (410) of the recycled carbon fiber layer (402). A decorative layer (306) is arranged relative to the top surface (316) of the first glass fiber layer (304); and The decorative layer (306), the first glass fiber layer (304), the recycled carbon fiber layer (402), and the second glass fiber layer (508) are exposed to one or more curing conditions to form the composite layered assembly (500).

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