Systems and methods for forming structure including bio-based resin product

Abstract

To provide methods for forming structures having a bio-based resin product that may be used on or within an aircraft.SOLUTION: A method of forming a structure includes positioning a first layer component 102 on a portion of a top surface of a second layer component 104, and positioning a third layer component 106 on a portion of a bottom surface of the second layer component in order to form a layered material assembly 100. The first layer component and the third layer component are configured to be manufactured of a first fabric and a bio-based resin product, and the second layer component is configured to be manufactured of a second material and the bio-based resin product. The method includes exposing the layered material assembly to one or more curing conditions in order to create a cured material assembly, and forming the cured material assembly into the structure configured to be disposed onboard an aircraft system.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE

[0001] Embodiments of the present disclosure generally relate to systems and methods for forming structures having bio-based resin articles that may be used on or within aircraft. [Background technology]

[0002]

[0002] Traditionally, aircraft structures and / or panels, such as sidewall panels, bin panels, etc., are manufactured from phenolic resins, plastic materials, or other materials that may be derived from fossil fuels. These fossil fuel-based materials provide lightweight, inexpensive products that can be used to form structures, panels, and surfaces within an aircraft.

[0003]

[0003] However, phenolic resin materials are not bio-based and are made from petroleum-based raw materials. For example, when an airplane structure deteriorates, it may be necessary to remove the deteriorated structure from the aircraft system and replace it with a new, undegraded structure. However, the removed deteriorated structure cannot be recycled and may instead be sent to a landfill or other waste collection system. However, as can be understood, non-bio-based products result in the generation of a significant amount of waste. Summary of the Invention

[0004] There is a need to form structures that can be used in vehicles and / or buildings that can be made from non-petroleum based organic materials, such as bio-based resin products.

[0005] With these needs in mind, certain embodiments of the present disclosure provide systems and methods that include bonding a first layer component to a second layer component and bonding a third layer component to the second layer component to form a layered material assembly. For example, a bottom surface of the first layer component may be bonded to a portion of a top surface of the second layer component, and a top surface of the third layer component may be bonded to a portion of a bottom surface of the second layer component to position the second layer component between the first and third layer components. Optionally, a fourth layer component may be bonded to a bottom surface of the third layer component.

[0006] In at least one embodiment, one or more of the layer components can include a bio-based resin product. As one example, the first layer component and / or the third layer component can be made of a fabric pre-impregnated with a bio-based resin product, such as a polyfurfuryl alcohol (PFA) resin product. Additionally, the second layer component can be made of a material that has been exposed to the bio-based resin product.

[0007] In at least one embodiment, the layered material assembly may be exposed to one or more curing, bonding, or joining conditions (e.g., heat, pressure, humidity, etc.) to cure, bond, or bond the layer components together. The cured material assembly may be formed into one or more structures that may be installed in an aircraft system, such as a sidewall panel or a stowage bin panel of the aircraft system. For example, the cured material assembly may be stamped, pressed, molded, etc. into one or more structures that may be installed in an aircraft system.

[0008] In at least one other embodiment, exposing the layered material assembly to one or more curing conditions may change one or more properties of one or more materials of the first layer component, the second layer component, and / or the third layer component. For example, exposure to curing conditions may change the hardness of one of the materials, the elasticity of one of the materials, the tensile strength of one of the materials, etc.

[0009] Certain embodiments of the present disclosure provide a layered material assembly including a first layer component, a second layer component bonded to the first layer component, and a third layer component bonded to the second layer component. The first layer component and the third layer component can be made of a first fabric and a bio-based resin product. The second layer component can be made of a second material and a bio-based resin product. The bio-based resin product can be dispersed throughout the first fabric, thereby impregnating the first fabric with the bio-based resin product. The bio-based resin product can be directed toward an exterior or exterior surface of the second material. For example, the second material can be coated with the bio-based resin product. In one embodiment, the bio-based resin product can be impregnated, soaked, spread, or dispersed into one or more interior surfaces of the second material.

[0010]

[0010] Several embodiments of the present disclosure provide a method including disposing a first layer component on a portion of an upper surface of a second layer component and disposing a third layer component on a portion of a lower surface of the second layer component. The first layer component and the third layer component may be made of a first fabric and a bio-based resin product, and the second layer component may be made of a second material and a bio-based resin product. The layered material assembly may be exposed to one or more curing conditions to create a cured material assembly. The cured material assembly may be formed into a structure that can be installed in an aircraft system. [Brief explanation of the drawings]

[0011] [Figure 1]

[0011] An exploded perspective view of a layered material assembly according to one embodiment of the present disclosure is shown. [Figure 2]

[0012] 2 illustrates an exploded side view of the layered material assembly shown in FIG. 1. [Figure 3]

[0013] 1 illustrates an exploded side view of a layered material assembly according to one embodiment of the present disclosure. [Figure 4]

[0014] 1 shows a flowchart of a method according to one embodiment of the present disclosure. [Figure 5]

[0015] 1 illustrates a perspective front view of an aircraft according to one embodiment of the present disclosure. [Figure 6]

[0016] 1 illustrates a perspective interior view of an interior cabin of a vehicle according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0012]

[0017] The foregoing summary, as well as the following detailed description of specific embodiments, will be better understood when read in conjunction with the accompanying drawings. As used herein, the use of the singular form "a" or "an" preceding an element or step does not necessarily exclude a plurality of such elements or steps. Furthermore, references to "one embodiment" are not intended to be interpreted as excluding the existence of additional embodiments that incorporate features described herein. Furthermore, embodiments that "comprising" or "having" one or more elements having certain conditions may include additional elements that do not have those conditions (unless expressly stated otherwise).

[0013]

[0018] As described herein, embodiments of the present disclosure provide systems and methods for forming a layered material assembly including one or more fabrics and a bio-based resin product, curing the layered material assembly, and forming the cured material assembly into one or more structures. The one or more formed structures may be coupled to or disposed within a system, such as an aircraft system or other vehicle system, a building, or other stationary structure. The layered material assembly may be formed by bonding a first layer component to a first side of a second layer component and a third layer component to a second side of the second layer component.

[0014]

[0019] In at least one embodiment, the first, second, and / or third layer components can be formed and / or manufactured from a fabric or other textile material, and the fabric material can be exposed to the bio-based resin product. For example, the bio-based resin product can be sprayed onto the fabric, onto a honeycomb sheet, or the fabric can be immersed or placed in a bathtub or pool of the liquid form of the bio-based resin product. In one embodiment, the bio-based resin product can be a polyfurfuryl alcohol (PFA) resin product or another material derived from natural and / or biological sources. For example, the bio-based resin product can be a non-petroleum-based organic material derived from biomass.

[0015]

[0020] In one or more embodiments, two or more of the layer components may be manufactured from the same, substantially the same, or one or more common materials. Optionally, two or more of the layer components may be manufactured via the same or a common manufacturing process. Optionally, two or more of the layer components may have one or more common properties (e.g., hardness, elasticity, etc.). Optionally, one or more of the layer components may include one or more attributes (e.g., design, color, texture, features, etc.) on the exterior or outer surface of the layer component. The one or more attributes may be based on a location within a vehicle and / or building structure where the structure formed by the layered material assembly may be located.

[0016]

[0021] In at least one embodiment, a layered material assembly of multiple layer components may be exposed to one or more curing, bonding, or bonding conditions to chemically and / or physically bond, bond, and / or attach the multiple layer components together to form a cured material assembly. The cured material assembly may be molded, stamped, formed, etc. into one or more structures that may be placed and / or connected to a vehicle, building, or alternative system. In at least one embodiment, curing and forming the structure may be completed in a single manufacturing process. In alternative embodiments, forming the cured material assembly and forming the structure may be completed in two or more different manufacturing processes.

[0017]

[0022] FIG. 1 illustrates an exploded perspective view of a layered material assembly 100, and FIG. 2 illustrates an exploded side view of the layered material assembly 100, according to one embodiment of the present disclosure. In the illustrated embodiment, the layered material assembly 100 includes a first layer component 102, a second layer component 104, and a third layer component 106. The first layer component 102 includes a first upper surface 108 and a first lower surface 118, the second layer component 104 includes a second upper surface 110 and a second lower surface 120, and the third layer component 106 includes a third upper surface 112 and a third lower surface 122.

[0018]

[0023] The layered material assembly 100 can be formed by connecting a first lower surface 118 of the first layer component 102 to a portion of the second upper surface 110 of the second layer component 104, and connecting a second lower surface 120 of the second layer component 104 to a portion of the third upper surface 112 of the third layer component 106.

[0019]

[0024] In one or more embodiments, one or more of the first layer component 102 or the third layer component 106 can be made of a first fabric and a bio-based resin product. The first fabric can be a woven and / or nonwoven fabric or fabric material. The fabric can be made of and / or include fiberglass, carbon fiber, polyaramid, etc. In one or more embodiments, the first layer component 102 and the third layer component 106 can be made of the same first fabric. In alternative embodiments, the first layer component 102 can be made of a fabric having one or more first characteristics (e.g., weight, thickness, weave structure, raw material, etc.), and the third layer component 106 can be made of a different fabric having one or more different second characteristics (e.g., different weight, thickness, weave structure, fiber material, etc.) relative to the fabric of the first layer component 102.

[0020]

[0025] The bio-based resin product may be at least partially derived from one or more materials of natural and / or biological origin. For example, the bio-based resin product may be derived from one or more of plants, renewable agricultural materials, marine materials, forestry materials, or one or more other non-petroleum-based organic materials derived from biomass. In one or more embodiments, the bio-based resin product may be and / or include polyfurfuryl alcohol (PFA) resin or a PFA resin product that may be derived from biowaste (e.g., sugarcane). In one or more embodiments, the first layer component 102 and the third layer component 106 may be manufactured using the same or a common resin product. In alternative embodiments, the bio-based resin product used in the first layer component 102 may be different from and / or have one or more different properties than the bio-based resin product used in the third layer component 106.

[0021]

[0026] The first fabric of the first layer component 102 and / or the third layer component 106 can be exposed to, bonded to, pre-impregnated with, etc. the bio-based resin product. For example, the first fabric can be exposed to the bio-based resin product (e.g., by spray application, dipping or submersion application, etc.) such that the bio-based resin product extends through at least a portion of the first fabric and is bonded to one or more interior and / or exterior fibers of the first fabric. For example, the first fabric can be at least partially reinforced, formed, molded, etc. with the bio-based resin product.

[0022]

[0027] The second layer component 104 can be made of a second material and a bio-based resin product. In one or more embodiments, the second material can be made of paper or a paper product, which can include one or more synthetic fibers, such as an aramid fiber product (e.g., a para-aramid material, a meta-aramid material, etc.). For example, the second material can be made of paper or a paper product formed into a honeycomb sheet having a predetermined thickness.

[0023]

[0028] The bio-based resin product of the second layer component 104 can be the same or substantially the same as the bio-based resin product used in the first layer component 102 and / or the third layer component 106. In alternative embodiments, the bio-based resin product of the second layer component 104 can be different and / or have one or more different properties than the bio-based resin product used in the first layer component 102 and / or the third layer component 106. The second material of the second layer component 104 can be exposed to the bio-based resin product, such as by immersing, spraying, immersing, etc., the bio-based resin product onto the second material. For example, a honeycomb sheet of the second material can be immersed in a bathtub or pool of the bio-based resin product, whereby the bio-based resin product is applied to one or more interior and / or exterior surfaces of the second material to form the second layer component 104.

[0024]

[0029] In exemplary embodiments shown in FIGS. 1 and 2 , the layered material assembly includes three layers of material bonded together to form the layered material assembly. In one or more embodiments, the layered material assembly can be formed by four or more layers of material that can be bonded together. For example, FIG. 3 illustrates a layered material assembly 300 according to one embodiment of the present disclosure. The layered material assembly 300 includes a first layer component 302, a second layer component 304, a third layer component 306, and a fourth layer component 308. In one or more embodiments, the first, second, and third layer components 302, 304, 306 can be the same or substantially the same (e.g., the same or similar materials, materials having the same or similar material properties, etc.) as the first, second, and third layer components 102, 104, 106 shown in FIGS. 1 and 2 .

[0025]

[0030] The fourth layer component 308 can be coupled to a portion of the third layer component 306. In one or more embodiments, the fourth layer component 308 can include one or more materials that can be the same or similar to the first, second, and / or third layer components 302, 304, 306. For example, the fourth layer component can be the same or substantially the same as the third layer component 306. The layered material assembly can thereby include two or more layers of the same material (e.g., core material) disposed on one or both sides of the second layer component 304. In one or more embodiments, the layered material assembly can include one or more layers operatively coupled together and disposed on one side of the second layer component 304 (e.g., on the bottom surface of the second layer component 304) and / or one or more layers operatively coupled together and disposed on the other side of the second layer component 304 (e.g., on the top surface of the second layer component 304). In another embodiment, the fourth layer component 308 may be fabricated from one or more materials or material products that are different from the materials and / or products used to form the first, second, and third layer components 302, 304, 306.

[0026]

[0031] In one or more embodiments, fourth lower surface 310 of fourth layer component 308 may include one or more attributes or characteristics, such as a texture, an image, a color, a design arrangement, etc. Layered material assembly 300 may be used to form one or more structures and / or components that may be used within a system, a building, etc. The one or more attributes may be based at least in part on a location within the system and / or building where the structure may be located. For example, layered material assembly 300 may be used to form a portion of a sidewall panel of an aircraft system. The one or more attributes of fourth lower surface 310 may be based on the design and / or decorative requirements of the aircraft sidewall panel. In another embodiment, layered material assembly 300 may be formed into a structure that may be used within a building. Another material (e.g., wallpaper material, paint, etc.) may be applied to fourth lower surface 310 of fourth component 308 before the structure formed by layered material assembly 300 is installed within a building. The fourth lower surface 310 may include one or more attributes that may facilitate and / or encourage the application of a paint product applied to the fourth lower surface 310 of the fourth layer component 308 .

[0027]

[0032] In one or more embodiments, a layered material assembly may include two or more layers of layer components that may be bonded together to form the layered material assembly. The material(s) and / or product(s) used within each of the layer components may be based on one or more requirements of the structure formed by the layered material assembly (e.g., hardness requirements, thickness requirements, thermal requirements, material toxicity requirements, flammability requirements, aesthetic requirements, etc.).

[0028]

[0033] 4 shows a flowchart 400 of a method for forming a structure according to one embodiment of the present disclosure. At 402, a first layer component is bonded to a portion of a second layer component, and at 404, a third layer component is bonded to a portion of the second layer component. For example, the first, second, and third layer components are arranged such that the second layer component is disposed between the first and third layer components to form a layered material assembly. Optionally, the layered material assembly can be formed by disposing two or more identical first layer components on a first side of the second layer component and / or disposing two or more identical third layer components on a second side of the second layer component.

[0029]

[0034] At 406, the layered material assembly may be exposed to one or more curing conditions to create a cured material assembly. For example, exposing the layered material assembly to curing conditions may physically and / or chemically bond, cure, bond, etc. the layer components together. In one example, the layer components may be placed, stacked, and / or positioned together and placed in a curing device that may expose the layered materials to one or more bonding, joining, and / or curing conditions (e.g., temperature, humidity, pressure, etc.). For example, the cured material assembly may be formed by placing the layered material assembly in a vacuum bag and exposing it to one or more temperature, pressure, and / or humidity conditions to form the cured material assembly. As another example, the cured material assembly may be formed by using a metal die, metal die set, autoclave, etc.

[0030]

[0035] In one or more embodiments, exposing a layered material assembly to one or more curing conditions to create a hardened material assembly can change one or more properties of one or more of the first layer component, the second layer component, and / or the third layer component of the layered material assembly. For example, exposing a layered material assembly to heat, pressure, and / or humidity conditions to harden the layered material assembly can change the hardness, elasticity, tensile strength, toughness, ductility, one or more chemical properties, etc. of the layered material assembly. The change in one or more material properties can be based on the curing conditions (e.g., temperature level, pressure level, exposure time, etc.) used to form the hardened material assembly.

[0031]

[0036] At 408, the cured material assembly may be formed into one or more structures. In one or more embodiments, forming the material assembly into one or more structures 408 may occur simultaneously or substantially simultaneously with curing the material assembly 406. For example, the cured material assembly and the formed structure(s) may be created in the same manufacturing process, using the same manufacturing equipment, exposing the materials to the same conditions, etc. For example, the layered material assembly may be placed in a vacuum bag, which may be used to cure the layered material assembly and form the cured material assembly into a structure in a single manufacturing step.

[0032]

[0037] Optionally, the steps of curing the material assembly and forming the structure may be completed in two or more different manufacturing processes by using different tools, machines, and / or equipment and exposing the material to different curing and forming conditions. For example, step 408 may occur at a time after step 406. The cured material assembly may be exposed to different conditions in step 408. Step 408 of forming one or more structures may require the use of one or more different pieces of equipment, etc. For example, the cured material assembly may be placed into a metal die or metal die set that may be used to form the cured material assembly into a structure by applying heat and / or pressure to the cured material assembly. One or more structures may be formed by stamping, pressing, and / or molding the cured material assembly.

[0033]

[0038] In one or more embodiments, in step 408, the cured material assembly may be co-cured with one or more other materials, objects, other cured material assemblies, etc. For example, two or more portions of the cured material assembly may be formed together (e.g., molded and / or cured together) into a single structure.

[0034]

[0039] In one or more embodiments, a fourth layer component may be added to the cured material assembly before the cured material assembly is formed into one or more structures in step 408. For example, the fourth layer component may include one or more attributes that may be based on design and / or decorative requirements. Decorative surfaces and / or layers of the fourth layer component may be added in a press or die set along with the cured material assembly, whereby the formed structure is a common formed structure with the finished detailed assembly.

[0035]

[0040] In one or more embodiments, the equipment used to cure and / or form a structure (e.g., metal die(s), foam(s), vacuum bag(s), tool(s), etc.) can be the same equipment that can be used to form a non-bio-based structure (e.g., a structure including one or more phenolic resin products). For example, the same tool or die set can be used to form a structure with a bio-based resin product and to form a structure made of a non-bio-based material. In one or more embodiments, one or more curing conditions can be varied between forming a bio-based structure (e.g., with a bio-based resin product) and forming a non-bio-based structure (e.g., with a phenolic resin product). For example, the temperature or pressure conditions required to cure a bio-based resin product can be different from the temperature or pressure conditions required to cure a phenolic resin product.

[0036]

[0041] In one or more embodiments, the color and / or darkness level of a structure formed with a bio-based resin product may differ from the color and / or darkness level of a structure formed with a non-bio-based material. For example, a cured material assembly including a bio-based resin product may be formed into a sidewall panel that can be used in an aircraft system. The darkness hue of the formed sidewall panel may differ from the darkness hue of a sidewall panel that can be formed using a non-bio-based material. In one embodiment, the different color or darkness level of a structure formed with a bio-based resin may be sufficient to block a greater amount or level of sunlight at a window opening in the sidewall panel than the amount or level of sunlight that can be blocked by the non-bio-based material. For example, a sidewall panel formed with a non-bio-based material may require a secondary product to be added around a portion of the window opening in the sidewall panel to control the amount of sunlight that can penetrate into the interior cabin of the aircraft. For example, a secondary product would not need to be added to a sidewall panel formed using a structure formed with a bio-based resin product described herein.

[0037]

[0042] In one or more embodiments, the layered material assembly may be in the form of a roll, a sheet, etc., with the first, second, and third layer components arranged in the roll and / or sheet. As an example, a layered material assembly formed and / or maintained as a roll may be separated into a plurality of individual piece layered material assemblies. The individual piece layered material assemblies may be hardened and / or formed into a structure. Optionally, a layered material assembly formed or maintained as a sheet may be separated or divided into one or more pieces, such as based on the structure formed by the layered material assembly. Optionally, the layered material assembly and / or the hardened material assembly may be arranged, contained, handled, etc., by one or more additional and / or alternative methods.

[0038]

[0043] At 410, one or more structures formed from the hardened material assembly may be mounted and / or coupled to a system, such as an aircraft system. Figure 5 illustrates a perspective front view of an aircraft 500, according to one embodiment of the present disclosure. The aircraft 500 includes a propulsion system 512, which may include, for example, two turbofan engines 514. Optionally, the propulsion system 512 may include more engines 514 than are shown. The engines 514 are supported by wings 516 of the aircraft 500. In other embodiments, the engines 514 may be supported by a fuselage 518 and / or a tail 520. The tail 520 may also support a horizontal stabilizer 522 and a vertical stabilizer 524.

[0039]

[0044] The fuselage 518 of the aircraft 500 defines an interior cabin. The interior cabin may include interior sidewall panels, ceiling panels, and floor panels. The interior cabin may include a cockpit, one or more work areas (e.g., a galley, a crew baggage area, etc.), one or more passenger areas (e.g., first class, business class, economy class), and an aft area. Portions of the aircraft 500, such as the ceiling panels, sidewall panels, etc., may be formed from bio-based resin products as described herein.

[0040]

[0045] Optionally, instead of aircraft systems, embodiments of the present disclosure may be used with various other stationary and / or non-stationary structures. For example, bio-based resin products may be used to form one or more structures used in and / or within buildings or other vehicles, such as automobiles, buses, trains and railcars, watercraft, spacecraft, etc.

[0041]

[0046] FIG. 6 illustrates a perspective interior view of an interior cabin 600 of a vehicle (such as the aircraft 500 shown in FIG. 5 ) according to one embodiment of the present disclosure. The interior cabin 600 includes numerous structures that may be formed from the cured material assemblies described herein, such as with respect to FIGS. 1-4 . For example, a ceiling panel 602, a stowage bin panel and / or assembly 604, a sidewall panel 606, a ceiling cover 608, a doorway arch panel 610, a doorway side panel 612, a partition, a closet, a restroom wall, a light bulb, and / or other components of an aircraft system may be formed from a layered material assembly including a bio-based resin product, as described herein. In one or more embodiments, structures formed from the bio-based cured material assemblies described herein may be used and / or placed in new aircraft, replace existing structures in aircraft systems (e.g., be retrofitted to existing aircraft systems), etc.

[0042]

[0047] As described herein, embodiments of the present disclosure provide systems and methods for forming a structure from a layered material assembly, where at least one of the layer components of the layered material assembly is formed from a fabric or other product and a bio-based resin product. The layered material assembly made from the bio-based resin product can be formed into a structure that can be coupled to or installed on an aircraft. Embodiments of the present disclosure provide methods and systems for forming a structure using non-petroleum-based organic materials.

[0043]

[0048] Furthermore, the present disclosure includes embodiments according to the following clauses.

[0044]

[0049] Article 1.

[0050] bonding the first layer component to a portion of the second layer component; and

[0051] The method includes bonding a third layer component to a portion of the second layer component to form a layered material assembly, wherein the first layer component and the third layer component are configured to be made of a first fabric and a bio-based resin product, and the second layer component is configured to be made of a second material and the bio-based resin product.

[0045]

[0052] Article 2. The method of clause 1, further comprising bonding a first lower surface of the first layer component to a second upper surface of the second layer component, and bonding a second lower surface of the second layer component to a third upper surface of the third layer component.

[0046]

[0053] Article 3. 3. The method of any one of clauses 1 to 2, further comprising exposing the layered material assembly to one or more curing conditions to create a cured material assembly.

[0047]

[0054] Article 4. 4. The method of claim 3, wherein exposing the layered material assembly to the one or more curing conditions changes one or more properties of one or more of the first layer component, the second layer component, or the third layer component.

[0048]

[0055] Article 5. 4. The method of claim 3, further comprising forming the hardened material assembly into one or more structures configured to be installed on an aircraft.

[0049]

[0056] Article 6. 6. The method of clause 5, further comprising one or more of stamping, pressing, or molding the hardened material assembly to form the hardened material assembly into the one or more structures.

[0050]

[0057] Article 7. 7. The method of any one of clauses 1 to 6, wherein the first fabric is configured to be impregnated with the bio-based resin product to form the first layer component and the third layer component.

[0051]

[0058] Article 8. 8. The method of any one of clauses 1 to 7, wherein the bio-based resin product is configured to be applied to one or more exterior surfaces of the second material to form the second layer component.

[0052]

[0059] Article 9. 9. The method of any one of clauses 1 to 8, wherein a third upper surface of the third layer component is configured to be bonded to a portion of the second lower surface of the second layer component, the method further comprising bonding a fourth upper surface of a fourth layer component to a portion of the third lower surface of the third layer component, the fourth layer component including one or more attributes disposed on the fourth lower surface of the fourth layer component.

[0053]

[0060] Article 10. 1. A layered material assembly comprising:

[0061] a first layer component;

[0062] a second layer component configured to be operatively coupled to the first layer component; and

[0063] a third layer component configured to be operably coupled with the second layer component, the second layer component configured to be disposed between the first layer component and the third layer component;

[0064] The first layer component and the third layer component are configured to be made of a first fabric and a bio-based resin product;

[0065] The layered material assembly, wherein the second layer component is configured to be made from a second material and the bio-based resin product.

[0054]

[0066] Article 11. The layered material assembly described in clause 10, wherein the first layer component includes a first upper surface and a first lower surface, the second layer component includes a second upper surface and a second lower surface, and the second upper surface of the second layer component is configured to be operably coupled to a portion of the first lower surface of the first layer component.

[0055]

[0067] Article 12. The layered material assembly described in clause 11, wherein the third layer component includes a third upper surface and a third lower surface, and the third upper surface of the third layer component is configured to be operably coupled to a portion of the second lower surface of the second layer component.

[0056]

[0068] Article 13. 13. The layered material assembly of any one of clauses 10 to 12, wherein the bio-based resin product is a polyfurfuryl alcohol (PFA) resin product.

[0057]

[0069] Article 14. 14. The layered material assembly of any one of clauses 10 to 13, wherein the first fabric is configured to be impregnated with the bio-based resin product to form the first layer component and the third layer component.

[0058]

[0070] Article 15. 15. The layered material assembly of any one of clauses 10 to 14, wherein the bio-based resin product is configured to be added to one or more exterior surfaces of the second material to form the second layer component.

[0059]

[0071] Clause 16. The layered material assembly of any one of clauses 10 to 15, wherein the first layer component, the second layer component, and the third layer component are configured to be exposed to one or more curing conditions to form a cured material assembly.

[0060]

[0072] Article 17. 17. The layered material assembly of claim 16, wherein the first layer component, the second layer component, and the third layer component are configured such that one or more properties of one or more of the first layer component, the second layer component, or the third layer component change in response to exposure to the one or more curing conditions.

[0061]

[0073] Article 18. 17. The layered material assembly of clause 16, wherein the hardened material assembly is configured to be formed into one or more structures configured to be installed on an aircraft.

[0062]

[0074] Article 19. 19. The layered material assembly of clause 18, wherein the hardened material assembly is configured to be formed into the one or more structures by one or more of stamping, pressing, or molding the hardened material assembly.

[0063]

[0075] Article 20 1. A method of forming a structure, comprising:

[0076] disposing a first layer component on a portion of an upper surface of a second layer component;

[0077] disposing a third layer component on a portion of the underside of the second layer component to form a layered material assembly, the first layer component and the third layer component being configured to be made of a first fabric and a bio-based resin product, and the second layer component being configured to be made of a second material and the bio-based resin product;

[0078] exposing the layered material assembly to one or more curing conditions to create a cured material assembly; and

[0079] forming the hardened material assembly into the structure configured to be installed on an aircraft.

[0064]

[0080] As described herein, embodiments of the present disclosure provide bio-based material structures that can be formed using one or more bio-based resin products and that can be coupled to and / or used within an aircraft. Furthermore, embodiments of the present disclosure provide efficient methods for preparing and forming bio-based resin product structures that can be installed with new aircraft systems, retrofitted to existing aircraft systems, etc. Bio-based structures can be formed using one or more tools, stamps, die sets, etc. that can be used to form non-bio-based structures.

[0065]

[0081] For purposes of describing the embodiments of the present disclosure, various spatial and directional terms may be used, such as top, bottom, lower, center, sideways, horizontal, vertical, front, etc., but it should be understood that such terms are used solely with reference to the orientations shown in the drawings. These orientations may be flipped, rotated, or otherwise changed so that top becomes bottom, bottom becomes top, horizontal becomes vertical, etc.

[0066]

[0082] As used herein, a structure, limitation, or element that is "configured to" perform an task or operation is structurally shaped, configured, or adapted specifically to correspond to the task or operation. For clarity and to avoid doubt, an object that can merely be modified to perform a task or operation is not "configured / set up to" perform a task or operation as used herein.

[0067]

[0083] It should be understood that the above description is intended to be illustrative, not limiting. For example, the above-described examples (and / or aspects thereof) can be used in combination with each other. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the various embodiments of the present disclosure without departing from the scope of the present disclosure. While the dimensions and types of materials described herein are intended to define aspects of the various embodiments of the present disclosure, the examples are by no means limiting, but are illustrative examples. Many other examples will be apparent to those skilled in the art upon reviewing the above description. The scope of the various embodiments of the present disclosure should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. In the accompanying claims and the detailed description herein, the words "including" and "in which" are used as the plain English equivalents of the words "comprising" and "wherein," respectively. Furthermore, terms such as "first," "second," and "third" 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 means-plus-function form, and are not intended to be construed under 35 U.S.C. §112(f) unless such claim limitations expressly use the phrase "means for," followed by a statement of function lacking further structure.

[0068]

[0084] The description herein uses examples to disclose various embodiments of the present disclosure, including the best mode, and to enable any person skilled in the art to practice various embodiments of the present disclosure, including making and using any device or system and practicing any methods incorporated therein. The patentable scope of various examples of the present disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if the examples have structural elements that do not differ from the literal language of the claims, or if the examples include equivalent structural elements that differ only insignificantly from the literal language of the claims.

Claims

1. bonding the first layer component (102) to a portion of the second layer component (104); and bonding a third layer component (106) to a portion of the second layer component (104) to form a layered material assembly (100); The method, wherein the first layer component (102) and the third layer component (106) are configured to be made of a first fabric and a bio-based resin product, and the second layer component (104) is configured to be made of a second material and the bio-based resin product.

2. 2. The method of claim 1, further comprising bonding a first lower surface (118) of the first layer component (102) to a second upper surface (110) of the second layer component (104), and bonding a second lower surface (120) of the second layer component (104) to a third upper surface (112) of the third layer component (106).

3. The method of claim 1 , further comprising exposing the layered material assembly (100) to one or more curing conditions to create a cured material assembly.

4. 4. The method of claim 3, wherein exposing the layered material assembly (100) to the one or more curing conditions changes one or more properties of one or more of the first layer component (102), the second layer component (104), or the third layer component (106).

5. The method of claim 3 , further comprising forming the hardened material assembly into one or more structures configured to be installed on an aircraft (500).

6. The method of claim 5 , further comprising one or more of stamping, pressing, or molding the hardened material assembly to form the hardened material assembly into the one or more structures.

7. 2. The method of claim 1, wherein the first fabric is configured to be impregnated with the bio-based resin product to form the first layer component (102) and the third layer component (106).

8. 10. The method of claim 1, wherein the bio-based resin product is configured to be applied to one or more exterior surfaces of the second material to form the second layer component (104).

9. 10. The method of claim 1, wherein a third upper surface (112) of the third layer component (306) is configured to be bonded to a portion of the second lower surface (120) of the second layer component (304), the method further comprising bonding a fourth upper surface (308) to a portion of the third lower surface (122) of the third layer component (306), the fourth layer component (308) including one or more attributes disposed on a fourth lower surface (310) of the fourth layer component (308).

10. A layered material assembly (100) comprising: a first layer component (102); a second layer component (104) configured to be operatively coupled with the first layer component (102); and a third layer component (106) configured to be operably coupled to the second layer component (104), the second layer component (104) configured to be disposed between the first layer component (102) and the third layer component (106); the first layer component (102) and the third layer component (106) are configured to be made of a first fabric and a bio-based resin product; The layered material assembly (100), wherein the second layer component (104) is configured to be made from a second material and the bio-based resin product.

11. 11. The layered material assembly (100) of claim 10, wherein the first layer component (102) includes a first upper surface (108) and a first lower surface (118), and the second layer component (104) includes a second upper surface (110) and a second lower surface (120), and the second upper surface (110) of the second layer component (104) is configured to be operably coupled to a portion of the first lower surface (118) of the first layer component (102).

12. 12. The layered material assembly (100) of claim 11, wherein the third layer component (106) includes a third upper surface (112) and a third lower surface (122), and the third upper surface (112) of the third layer component (106) is configured to be operably coupled with a portion of the second lower surface (120) of the second layer component (104).

13. The layered material assembly (100) of claim 10, wherein the bio-based resin product is a polyfurfuryl alcohol (PFA) resin product.

14. 11. The layered material assembly (100) of claim 10, wherein the first fabric is configured to be impregnated with the bio-based resin product to form the first layer component (102) and the third layer component (106).

15. 11. The layered material assembly (100) of claim 10, wherein the bio-based resin product is configured to be applied to one or more exterior surfaces of the second material to form the second layer component (104).

16. 11. The layered material assembly (100) of claim 10, wherein the first layer component (102), the second layer component (104), and the third layer component (106) are configured to be exposed to one or more curing conditions to form a cured material assembly.

17. 17. The layered material assembly (100) of claim 16, wherein the first layer component (102), the second layer component (104), and the third layer component (106) are configured to change one or more properties of one or more of the first layer component (102), the second layer component (104), or the third layer component (106) in response to exposure to the one or more curing conditions.

18. 17. The layered material assembly (100) of claim 16, wherein the cured material assembly is configured to be formed into one or more structures configured to be installed on an aircraft (500).

19. 20. The layered material assembly (100) of claim 18, wherein the hardened material assembly is configured to be formed into the one or more structures by one or more of stamping, pressing, or molding the hardened material assembly.

20. 1. A method of forming a structure, comprising: disposing a first layer component (102) on a portion of an upper surface (110) of a second layer component (104); disposing a third layer component (106) on a portion of the lower surface (120) of the second layer component (104) to form a layered material assembly (100), wherein the first layer component (102) and the third layer component (106) are configured to be made of a first fabric and a bio-based resin product, and the second layer component (104) is configured to be made of a second material and the bio-based resin product; exposing the layered material assembly (100) to one or more curing conditions to create a cured material assembly; and forming the hardened material assembly into the structure configured to be installed on an aircraft (500).

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