System and method for forming a composite laminated assembly containing nonwoven carbon fiber material

Abstract

The present invention provides a system and method for forming a composite laminated assembly containing nonwoven carbon fiber material. [Solution] A system and method for forming a composite laminated assembly (300) includes the step of placing a first glass fiber layer (304) between a nonwoven carbon fiber layer (302) and a decorative layer (306). 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 laminated assembly (300).

Description

[Technical Field]

[0001] Examples of the present disclosure generally relate to systems and methods for forming composite laminate assemblies comprising non-woven carbon fiber and glass fiber materials that can be used on or in an aircraft. [Background Art]

[0002] Conventionally, cargo liners used for lining surfaces within aircraft cargo sections are manufactured from glass fiber coated with a phenolic or cyanate ester resin and cured with a decorative film such as Tedlar. Cargo liners can be subjected to excessive wear based on cargo moving into and out of the aircraft cargo section. Liners may require repair or replacement after withstanding a certain level of wear.

[0003] Furthermore, cargo liners are designed to meet specific oil burn or other flammability requirements. However, while glass fiber materials can meet certain flammability requirements, the materials remain flammable. As can be appreciated, there is a need for an improved liner manufactured from non-combustible materials that has improved durability and is capable of withstanding higher levels of wear. [Summary of Invention] [Problem to be Solved by the Invention]

[0004] There is a need for a liner that can be installed in an aircraft, such as within an aircraft cargo section. The liner can be manufactured from multiple layers of materials that are semi-rigid, non-combustible, have improved durability, and / or are capable of withstanding high levels of wear. With these needs in mind, certain examples of the present disclosure provide systems and methods comprising the step of positioning a first glass fiber layer between a non-woven carbon fiber layer and a decorative layer. The decorative layer, the first glass fiber layer, and the non-woven carbon fiber layer are exposed to one or more curing conditions to form a composite laminate assembly. [Means for Solving the Problem]

[0005] In one example, the step of exposing the decorative layer, the first glass fiber layer, and the nonwoven carbon fiber layer to curing conditions alters the 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 the steps of arranging 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 laminate assembly.

[0007] In one example, the method may include the step of 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 components may be made from recycled nonwoven carbon fiber material. Optionally, the first glass fiber layer may be made from a thermoplastic polymer or other material, and the first glass fiber layer may be placed on one or more nonwoven carbon fiber components. Heat and / or pressure may be applied to the first glass fiber layer and one or more nonwoven carbon fiber components to form a subassembly comprising 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, a composite laminated assembly may be machined to form a laminated product, which may be installed within an aircraft system.

[0010] A particular example of the present disclosure provides a composite laminate assembly comprising a nonwoven carbon fiber layer, a first glass fiber layer having a bottom surface operably bonded to the top surface of the nonwoven carbon fiber layer, and a decorative layer that can be operably bonded 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 laminate assembly.

[0011] An example of the present disclosure provides a method for forming a composite laminate assembly, comprising the steps of: positioning the bottom surface of a first glass fiber layer facing the top surface of a recycled carbon fiber layer made of nonwoven carbon fiber material; positioning the top surface of a second glass fiber layer facing the bottom surface of the recycled carbon fiber layer; and positioning 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 a composite laminate assembly. [Brief explanation of the drawing]

[0012] [Figure 1] This is a perspective view of a manufacturing process for forming a nonwoven carbon fiber layer, as shown in this disclosure. [Figure 2] This figure shows a nonwoven carbon fiber layer according to an example of the present disclosure. [Figure 3] This is an exploded perspective view of a composite laminated assembly according to an example of the present disclosure. [Figure 4] This is an exploded perspective view of a composite laminated assembly according to an example of the present disclosure. [Figure 5] This is an exploded perspective view of a composite laminated assembly according to an example of the present disclosure. [Figure 6] This is a flowchart of a method for forming a composite laminated assembly according to an example of the present disclosure. [Figure 7] This is a front perspective view of an aircraft system, as an example of this disclosure. [Figure 8] Figure 7 is an internal perspective view of the aircraft system. [Modes for carrying out the invention]

[0013] The above overview, as well as the following detailed descriptions of specific examples, will be better understood in conjunction with the attached drawings. In this specification, elements or steps described in the singular and followed by the words “a certain” or “one” should be understood not to necessarily exclude the possibility that those elements or steps are plural. Furthermore, references to “one example” are not intended to be interpreted as excluding the existence of additional examples that also incorporate the listed features. Moreover, unless explicitly stated otherwise, examples “comprising” or “having” one or more elements having a particular condition may include additional elements that do not have that condition.

[0014] As described herein, examples of the present disclosure provide systems and methods for forming a laminated assembly comprising one or more glass fiber layers, a nonwoven carbon fiber layer, and optionally a decorative layer. In one example, the laminated assembly may include a glass fiber layer positioned between the decorative layer and the nonwoven carbon fiber layer. In another example, the laminated assembly may include a first glass fiber layer positioned between the decorative layer and the nonwoven carbon fiber layer, and a second glass fiber layer positioned on the second side of the nonwoven carbon fiber layer. For example, the nonwoven carbon fiber layer may be positioned between the first glass fiber layer and the second glass fiber layer.

[0015] The layers may be exposed to one or more curing, bonding, or bonding conditions to chemically and / or physically bond, combine, and / or attach multiple layer components to form a cured assembly. The cured composite laminated assembly may be formed into one or more structures using one or more secondary manufacturing processes. One or more formed structures may be coupled to or placed within a system such as an aircraft system or other vehicle system, a building or other fixed structure.

[0016] In one example, the nonwoven carbon fiber layer may be formed from one or more nonwoven carbon fiber components, sheets, elements, etc. For example, one or more rolls of nonwoven carbon fiber may be exposed to pressure and / or heat to form a rigid nonwoven carbon fiber layer by molding nonwoven carbon fiber pieces together. In one example, the nonwoven carbon fiber components may be made from recycled carbon fiber material. In one example, the glass fiber layer may be made from a thermoplastic polymer or other material and may be exposed to pressure and / or heat together with the nonwoven carbon fiber to form a subassembly of the glass fiber layer and the nonwoven carbon fiber layer. In another example, the glass fiber layer may be made from a thermosetting glass fiber material or an alternative material and may be cured together with the nonwoven carbon fiber layer and decorative layer to form a composite laminate assembly. In yet another example,

[0017] Figure 1 shows a perspective view of a manufacturing process for forming a nonwoven carbon fiber layer according to an example of the present disclosure. The nonwoven carbon fiber layer may be formed by stacking one or more nonwoven carbon fiber components 102A to 102C on top of each other and applying heat and / or pressure with rolling elements 104A, 104B, etc. For example, the components 102A to 102C may be in the shape of a sheet, roll, etc., and each of the components 102A to 102C may be manufactured from a nonwoven carbon fiber material. In at least one example, one or more of the components 102A to 102C may be manufactured from recycled nonwoven carbon fiber material.

[0018] Figure 2 shows a nonwoven carbon fiber layer 202 according to an example of the present disclosure. The nonwoven carbon fiber layer 202 may be formed by applying heat and / or pressure to nonwoven components 102A to 102C with rolling elements 104A to 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.

[0019] In the illustrated example, the nonwoven carbon fiber layer 202 is formed by processing components 102A to 102C with a double belt press while exposing the components to a temperature of approximately 700°F. For example, recycled nonwoven carbon fiber components may be processed by continuous or semi-continuous compression molding steps to produce a semi-flexible liner or laminate. In another example, nonwoven components 102A to 102C may be placed in a stamping press, mold or the like with pressure and / or heat applied to form carbon fiber layer 202. By exposing the components to pressure conditions and / or heat conditions, components 102A to 102C may be molded, formed, or bonded into nonwoven carbon fiber layer 202. For example, components 102A to 102C may be combined together into a single coherent overall layer. In one example, molded carbon fiber layer 202 may have greater rigidity, hardness, strength and the like than nonwoven components 102A to 102C. For example, applying heat and / or pressure to components 102A to 102C changes one or more material properties of components 102A to 102C during formation of nonwoven carbon fiber layer 202.

[0020] In one example, the number of nonwoven carbon fiber components 102A to 102C used to form layer 202 may be determined based on the basis weight for the system in which layer 202 may be used, such as an aircraft system. Nonwoven carbon fiber layer 202 may be formed of a single nonwoven component, two nonwoven components, or three or more nonwoven components. As another example, the number of nonwoven carbon fiber components 102A to 102C used to form layer 202 may be based on availability of one or more different weights, thicknesses, sizes and the like of the components.

[0021] In one or more examples, the materials and / or products used within each layer of composite laminate assembly 300 may be based on one or more requirements of the structure formed by the composite laminate assembly (e.g., durability requirements, weight requirements, thickness requirements, thermal requirements, material toxicity requirements, flammability requirements, aesthetic requirements, etc.).

[0022] Fig. 3 shows an exploded perspective view of a composite laminate assembly 300 according to one example of the present disclosure. The composite laminate assembly 300 includes a non-woven carbon fiber layer 302 formed from one non-woven carbon fiber component 102A. The composite laminate 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 non-woven carbon fiber layer 302. For example, a bottom surface 314 of the first glass fiber layer 304 faces toward and is bonded to a top surface 312 of the non-woven carbon fiber layer 302. A top surface 316 of the first glass fiber layer 304 faces toward and is bonded to a bottom surface 318 of the decorative layer 306.

[0023] In one example, the first glass fiber layer 304 may be a glass fiber material that can be coated with a thermoplastic polymer coating. Optionally, 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 thermoset glass fiber material that can be impregnated with a resin product.

[0024] The decorative layer 306 may include one or more features (e.g., color, patterns, illustrations, textured elements such as bumps or dimples, etc.) disposed on a top surface 320 of the decorative layer 306. The one or more features may be based on a final installation position where the composite laminate assembly 300 may be disposed.

[0025] The decorative layer 306, the first glass fiber layer 304, and the non-woven carbon fiber layer 302 may be exposed to one or more curing conditions to form a cured and assembled composite laminate assembly 300. For example, exposing the laminate assembly to curing conditions may physically and / or chemically join, cure, bond, etc., the component layers together such that one or more properties of one or more of the layers are altered.

[0026] In one example, the layer components 302, 304, and 306 may be arranged together, laminated, and / or positioned, and placed in a curing apparatus that can expose the laminated material to one or more bonding, joining, and / or curing conditions (e.g., temperature, humidity, pressure, etc.). In one example, the cured composite laminated assembly 300 may be formed by placing the layers 302, 304, and 306 in a metal die, metal die set, autoclave, oven, etc., and exposing the layers to one or more curing conditions. In another example, the cured composite laminated assembly 300 may be formed by placing the layers 302, 304, and 306 in a vacuum bag and exposing the layers to one or more of the temperature, pressure, and / or humidity conditions to form a cured material assembly.

[0027] In one or more examples, the decorative layer 306 may include an adhesive layer or one or more adhesive elements (not shown) operably bonded to the bottom surface 318 of the decorative layer 306. For example, the adhesive layer or adhesive element may be a pressure-sensitive adhesive, adhesive liner, adhesive paste, etc., which can be used to bond the bottom surface 318 of the decorative layer 306 to the top surface 316 of the first glass fiber layer 304, such as during exposure to curing conditions of the layer.

[0028] In one example, the first glass fiber layer 304 may be made of thermoplastic coated glass fiber material, and the first glass fiber layer 304 may be molded together with the nonwoven carbon fiber layer 302 during the compression molding stage. For example, the first glass fiber layer 304 may be placed together with the nonwoven carbon fiber component 102 (shown in Figure 1), so that the first glass fiber layer 304 and the component 102 are processed together by rolling elements 104A-104B to form a subassembly including the first glass fiber layer 304 and the nonwoven carbon fiber layer 202. After the first glass fiber layer 304 is molded together with the nonwoven carbon fiber layer 202, the decorative layer 306 may be positioned on the upper surface 316 of the first glass fiber layer 304, and the three layers may be exposed to curing conditions to form a composite laminate assembly 300.

[0029] In one example, the curing conditions may vary depending on whether the first glass fiber layer 304 was 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, the layer may undergo a first set of curing conditions to form the composite laminate assembly 300. Alternatively, if the first glass fiber layer 304 is molded together with the nonwoven carbon fiber layer 202, the layer may undergo a different second set of curing conditions.

[0030] Figure 4 shows a composite laminated assembly 400 according to another example of the present disclosure. The composite laminated 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 of two nonwoven components 102A and 102B. For example, the two nonwoven components 102A and 102B may be processed by rolling elements 104A and 104B to form a molded nonwoven carbon fiber layer 402.

[0031] The 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.

[0032] The nonwoven carbon fiber layer 402, the first glass fiber layer 304, and the decorative layer 306 may be exposed to one or more curing conditions to form a cured and assembled composite laminate assembly 400. For example, exposure of the laminate assembly to curing conditions may physically and / or chemically bond, cure, or combine the constituent layers together so that the properties of one or more of the layers are altered.

[0033] Figure 5 shows a composite laminate assembly 500 according to another example of the present disclosure. The composite laminate assembly 500 includes a nonwoven carbon fiber layer 402 (formed from two nonwoven carbon fiber components 102A and 102B), a first glass fiber layer 304, and a decorative layer 306. The composite laminate assembly 500 also includes a second glass fiber layer 508 positioned 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 the bottom surface 410 of the nonwoven carbon fiber layer 402 and is bonded to it.

[0034] In one example, the first glass fiber layer 304 and the second glass fiber layer 508 may be made of the same or similar material. In one example, the first and second glass fiber layers may be made from a glass fiber material that can be coated with a thermoplastic polymer coating. Optionally, the thermoplastic coated glass fiber material may be impregnated with a resin product. In another example, the first and second glass fiber layers 304, 508 may be made from a thermosetting glass fiber material that can be impregnated with a resin product. Optionally, the first and second glass fiber layers 304, 508 may be made from an alternative composite material.

[0035] The decorative layer 306, the first glass fiber layer 304, the nonwoven carbon fiber layer 402, and the second glass fiber layer 508 may be exposed to one or more curing conditions to form a cured and assembled composite laminate assembly 500. For example, exposing the laminate assembly to curing conditions may physically and / or chemically bond, cure, or combine the constituent layers together so that the properties of one or more of the layers are altered.

[0036] In one example, the first and second glass fiber layers 304, 508 may be manufactured from a thermoplastic coated glass fiber material, and the first and second glass fiber layers 304, 508 may be molded together with the nonwoven carbon fiber layer 402 during the compression molding stage. For example, the nonwoven carbon fiber components 102A, 102B may be placed between the first and second glass fiber layers 304, 508, and then the first and second glass fiber layers 304, 508 and components 102A, 102B are machined together by rolling elements 104A-104B to form a subassembly including the first glass fiber layer 304, the second glass fiber layer 508, and the nonwoven carbon fiber layer 202. After the first and second glass fiber layers 304 and 508 are formed together with the nonwoven carbon fiber layer 202, the decorative layer 306 may be positioned on the upper surface 316 of the first glass fiber layer 304, and the four layers may be exposed to curing conditions to form a composite laminate assembly 500.

[0037] Figure 6 shows a flowchart 600 of a method for forming a composite laminated assembly according to an example of the present disclosure. In 602, the number of glass fiber layers to be included in the composite laminated assembly is selected. The number of glass fiber layers may be based on one or more requirements of the structure formed by the composite laminated assembly (e.g., durability requirements, weight requirements, thickness requirements, thermal requirements, material toxicity requirements, flammability requirements, aesthetic requirements, etc.). The composite laminated assembly may include one glass fiber layer (e.g., shown in Figure 3), two glass fiber layers (e.g., shown in Figure 5), or three or more glass fiber layers (not shown).

[0038] In 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, the glass fiber layer may be molded together with the nonwoven carbon fiber components. Alternatively, if the glass fiber layer is made of another material (e.g., a thermosetting material), the glass fiber layer does not need to be molded together with the nonwoven carbon fiber components. If the glass fiber layer is made of a thermoplastic material, the method flow proceeds to 606.

[0039] In 606, one or more nonwoven carbon fiber components (e.g., sheets, rolls, etc.) are positioned relative to a glass fiber layer. If one glass fiber layer is selected in 602, the glass fiber layer may be placed on one surface of the nonwoven component. If two glass fiber layers are selected in 602, the nonwoven carbon fiber component may be positioned between the two glass fiber layers. In 608, heat and / or pressure are applied to the nonwoven carbon fiber component and the glass fiber layer in order to form a subassembly containing the nonwoven carbon fiber layer and the glass fiber layer together. In one or more examples, exposure of the glass fiber layer and carbon fiber component to heat and / or pressure conditions may alter one or more properties of the glass fiber layer and / or carbon fiber component, such as hardness, elasticity, tensile strength, toughness, ductility, and one or more chemical properties.

[0040] In 610, the decorative layer is positioned on the upper surface of one of the glass fiber layers such that one of the glass fiber layers is positioned between the nonwoven carbon fiber layer and the decorative layer. In 616, the decorative layer, the glass fiber layer, and the nonwoven carbon fiber layer are exposed to one or more curing conditions to cure the layers together or to bond them in order to form a composite laminate assembly.

[0041] Returning to step 604, if the glass fiber layer is not manufactured from a thermoplastic polymer material, the method flow proceeds to 612. In 612, heat and / or pressure are applied to one or more nonwoven carbon fiber components to mold the components together to form a molded, rigid nonwoven carbon fiber layer. In one or more examples, exposure of carbon fiber components to heat and / or pressure conditions may alter one or more properties of the carbon fiber components, such as hardness, elasticity, tensile strength, toughness, ductility, and one or more chemical properties.

[0042] In 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. In 616, the decorative layer, the glass fiber layer and the nonwoven carbon fiber layer are exposed to one or more bonding, bonding and / or curing conditions (e.g., temperature, humidity, pressure, etc.) to form a cured composite laminate assembly.

[0043] In one or more examples, a cured composite laminate assembly may be machined, manipulated, cut, sliced, formed, or subjected to any alternative secondary manufacturing process to form a laminate that can be used in a system such as an aircraft system. Figure 7 shows a perspective front view of an aircraft 700 according to an example of the present disclosure. 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 those shown. The engines 714 are supported by the wings 716 of the aircraft 700. In another example, the engines 714 may be supported by the fuselage 718 and / or tail section 720. The tail section 720 may also support a horizontal stabilizer 722 and a vertical stabilizer 724.

[0044] The fuselage 718 of the aircraft 700 defines an interior cabin which may include interior side wall panels, ceiling panels, and floor panels. The interior cabin may include a cockpit, one or more work sections (e.g., a galley, a carry-on baggage area for personnel, etc.), one or more passenger sections (e.g., first class, business class, and coach sections), one or more storage sections (e.g., a cargo section), and a rear section. Parts of the aircraft 700, such as ceiling panels, side wall panels, or floor panels of the cargo section or any other section of the aircraft 700, may be formed from laminated assemblies including nonwoven carbon fiber layers as described herein.

[0045] Optionally, instead of aircraft systems, the examples of the present disclosure may be used with a variety of other fixed and / or non-fixed structures. For example, laminated assemblies comprising fiberglass and nonwoven carbon fiber laminates may be used to form one or more structures used on and / or inside buildings or other vehicles such as automobiles, buses, locomotives and trains, ships, and spacecraft.

[0046] Figure 8 shows a perspective view of an interior portion of a vehicle, such as a cargo section 800 of an aircraft 700 shown in Figure 7, according to an example of the present disclosure. The cargo section 800 includes a ceiling panel 802, a plurality of side panels 804, and a floor panel 806 defining the interior cargo section of the aircraft. In one or more examples, the cargo section 800 may include one or more liners 812, 814, 816, 818 which can be operably coupled to the ceiling panel, side panels, and / or floor panel via one or more fastening elements. Liners 812-818 may be manufactured in a composite laminate assembly (e.g., including one or more fiberglass layers, nonwoven carbon fiber layers, and decorative layers). For example, the composite laminate assembly may be machined, formed, cut, and joined to form laminate products of appropriate size and shape for installation in another section of an aircraft, in another type of vehicle (e.g., a ship), in a building or other fixed installation, etc., or may undergo any alternative secondary manufacturing process.

[0047] As described herein, examples of the present disclosure provide systems and methods for forming composite laminated assemblies comprising a nonwoven carbon fiber material, one or more glass fiber layers, and optionally a decorative layer. The composite laminated assemblies may be formed into structures that can be coupled to an aircraft or placed inside an aircraft, such as within the cargo section of an aircraft. The composite laminated assemblies may be used to form semi-rigid, highly abrasion-resistant, non-flammable liner structures for aircraft cargo interior linings. For example, the composite laminated assemblies may be non-flammable or may have improved flammability compared to laminated assemblies without nonwoven carbon fiber layers, assemblies with woven carbon fiber layers, etc. Furthermore, the composite laminated assemblies may have improved durability compared to assemblies without one or more glass fiber layers. For example, examples of the present disclosure provide systems and methods for forming structures that have improved flammability requirements and / or performance, improved durability, and improved sustainability (e.g., in response to the use of recycled nonwoven components), while having more opportunity to select materials to meet one or more requirements, compared to known material assemblies used to form liners installed within aircraft cargo sections.

[0048] Furthermore, this disclosure includes examples provided in the following clauses.

[0049] Clause 1: The steps include placing a first glass fiber layer between a nonwoven carbon fiber layer and a decorative layer, To form a composite laminated assembly, the process involves exposing a decorative layer, a first glass fiber layer, and a nonwoven carbon fiber layer to one or more curing conditions. Methods that include...

[0050] Clause 2: The method of Clause 1, wherein the step of exposing the decorative layer, the first glass fiber layer, and the nonwoven carbon fiber layer to one or more curing conditions alters the properties of one or more of the first glass fiber layer, the nonwoven carbon fiber layer, or the decorative layer.

[0051] Clause 3: The steps include: placing a second glass fiber layer on a nonwoven carbon fiber layer, To form a composite laminated assembly, the steps include exposing a decorative layer, a first glass fiber layer, a nonwoven carbon fiber layer, and a second glass fiber layer to one or more curing conditions. The method of clause 1 or 2, including the method of clause 1 or 2.

[0052] Clause 4: A method according to any one of the claims 1 to 3, further comprising the step of applying one or more heat or pressure to one or more nonwoven carbon fiber components in order to form a nonwoven carbon fiber layer.

[0053] Article 5: The method of Clause 4, wherein one or more nonwoven carbon fiber components are manufactured from recycled nonwoven carbon fiber material.

[0054] Clause 6: The first glass fiber layer is made of a thermoplastic material, and the method is as follows: The steps include: placing a first glass fiber layer on one or more nonwoven carbon fiber components; To form a subassembly including a nonwoven carbon fiber layer and a first glass fiber layer, the steps include applying one or more heat and / or pressure to one or more nonwoven carbon fiber components and the first glass fiber layer. The method of Clause 4, further including the method of Clause 4.

[0055] Article 7: The first glass fiber layer is manufactured by any of the methods of Clauses 1 to 6, wherein the first glass fiber layer is manufactured by either a thermosetting glass fiber composite or a thermoplastic glass fiber composite.

[0056] Clause 8: The method according to any of the clauses 1 to 7, wherein the first glass fiber layer is configured to be impregnated with a resin product.

[0057] Article 9: The steps include machining a composite laminated assembly to form a laminated product, Steps include installing the laminated product within the aircraft system and Any method of clauses 1 through 8, further including the above.

[0058] Clause 10: A composite laminated assembly, Nonwoven carbon fiber layer, A first glass fiber layer having a bottom surface operably bonded to the top surface of a nonwoven carbon fiber layer, A decorative layer operably bonded to the upper surface of the first fiberglass layer Equipped with, 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 a composite laminate assembly. Composite laminated assembly.

[0059] Clause 11: The invention further comprises a second glass fiber layer operably bonded to the bottom surface of a nonwoven carbon fiber layer, 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 in order to form a composite laminate assembly. Composite laminated assembly of Clause 10.

[0060] Article 12: A composite laminate assembly according to clause 11, wherein a first glass fiber layer and a second glass fiber layer are configured to be impregnated with a resin product.

[0061] Article 13: A composite laminate assembly according to clause 11, wherein the first glass fiber layer and the second glass fiber layer are manufactured from either a thermosetting glass fiber composite or a thermoplastic glass fiber composite.

[0062] Article 14: A composite laminate assembly according to any of clauses 10 to 13, wherein the nonwoven carbon fiber layer is configured to be manufactured from recycled nonwoven carbon fiber material.

[0063] Article 15: The first glass fiber layer is made of thermoplastic material. The first glass fiber layer is configured to be arranged on one or more nonwoven carbon fiber components, and the nonwoven carbon fiber layer is formed of one or more nonwoven carbon fiber components. A first glass fiber layer and one or more nonwoven carbon fiber components are configured to be exposed to one or more of heat and / or pressure in order to form a subassembly comprising the nonwoven carbon fiber layer and the first glass fiber layer. A composite laminated assembly according to any of clauses 10 to 14.

[0064] Article 16: A composite laminate assembly according to any one of the clauses 10 to 15, further comprising an adhesive layer positioned between the upper surface of the first fiberglass layer and the decorative layer in order to bond the decorative layer to the upper surface of the first fiberglass layer during exposure to one or more curing conditions.

[0065] Article 17: A method for forming a composite laminated assembly, The steps include: placing the bottom surface of a first glass fiber layer on the top surface of a recycled carbon fiber layer, wherein the recycled carbon fiber layer is made of a nonwoven carbon fiber material; The steps include: placing the upper surface of a second glass fiber layer on the bottom surface of a recycled carbon fiber layer; The steps include: placing a decorative layer on the upper surface of the first fiberglass layer; To form a composite laminated assembly, the steps include exposing a decorative layer, a first glass fiber layer, a recycled carbon fiber layer, and a second glass fiber layer to one or more curing conditions. Methods that include...

[0066] Article 18: The method of Clause 17, further comprising the step of applying one or more of pressure or heat to a nonwoven carbon fiber material in order to form a recycled carbon fiber layer.

[0067] Article 19: The first glass fiber layer and the second glass fiber layer are made of thermoplastic material, and the method is as follows: The steps include arranging a first glass fiber layer and a second glass fiber layer on a nonwoven carbon fiber material, To form a subassembly including a recycled carbon fiber layer, a first glass fiber layer, and a second glass fiber layer, the steps include applying one or more of heat and / or pressure to the first glass fiber layer, the second glass fiber layer, and the nonwoven carbon fiber material. The methods of Article 18, which further include the following.

[0068] Article 20: The steps include forming a composite laminated assembly into a laminated product, Steps include installing the laminated product within the aircraft system and Any method of Articles 17 to 19, further including the above.

[0069] As described herein, examples of the present disclosure provide structures formed by composite laminated assemblies comprising one or more nonwoven carbon fiber components and one or more glass fiber layers. The laminated assemblies may be coupled to and / or used in aircraft. Furthermore, examples of the present disclosure provide laminated assemblies having improved flammability, improved durability, and improved sustainability compared to laminated assemblies without nonwoven carbon fiber and / or glass fiber layers.

[0070] Various terms describing space and direction, such as top, bottom, underside, middle, side, horizontal, vertical, and front, can be used to describe embodiments of this disclosure, but it should be understood that such terms are used only in relation to the orientation shown in the drawings. Orientation can be reversed, rotated, or otherwise altered so that the upper part becomes the lower part, or vice versa, or horizontal becomes vertical.

[0071] As used herein, a structure, constraint, or element “configured to perform a task or work” is, in a manner corresponding to that task or work, specifically structurally formed, constructed, or adapted. For clarity and avoidance of doubt, an object that can only be modified to perform a task or work is not, as used herein, “configured to perform that task or work.”

[0072] It should be understood that the above description is intended to be illustrative and not limiting. For example, the examples (and / or embodiments thereof) described above can be used in combination with each other. In addition, numerous modifications can be made to adapt specific situations or materials to the teachings of the various examples of this disclosure without departing from their scope. The dimensions and types of materials described herein are intended to define embodiments of the various examples of this disclosure, but these examples are not intended to be limiting and are illustrative examples only. Numerous other examples will become apparent to those skilled in the art upon consideration of the above description. Therefore, the scope of the various examples of this disclosure should be determined by referring to the appended claims, along with the entire scope of equivalents given to such claims. In the appended claims and the detailed description herein, the terms “including” and “in which” are used as plain English equivalents of the terms “comprising” and “wherein,” respectively. Furthermore, terms such as “first,” “second,” and “third” are used merely as designations and are not intended to impose numerical requirements on those objects. Moreover, the following limitations of the claims are not written in means-plus-function form unless such limitations explicitly use the expression “means for” in conjunction with a functional statement that does not refer to a further structure, and are not intended to be interpreted under Section 112(f) of the U.S. Patent Act.

[0073] This written description discloses various examples of the disclosure, including in best mode, and uses examples to enable those skilled in the art to carry out the various examples of the disclosure, including the manufacture and use of any device or system, and the execution of any incorporated method. The patentable scope of the various examples of the disclosure is defined by the claims and may include other embodiments that a person skilled in the art could conceive. Such other examples are intended to be within the technical scope of the claims if they have structural elements that do not differ from the language of the claims, or if they include equivalent structural elements that do not differ substantially from the language of the claims. [Explanation of symbols]

[0074] 102 Nonwoven carbon fiber components 102A Nonwoven carbon fiber components 102B Nonwoven carbon fiber components 104A Rolling element 104B Rolling element 202 Nonwoven carbon fiber layer 300 Composite Laminated Assembly 302 Nonwoven carbon fiber layer 304 Glass fiber layer 306 Decorative layer 312 Top surface 314 Bottom 316 Top surface 318 Bottom 320 Top 400 composite laminated assemblies 402 Nonwoven carbon fiber layer 410 Bottom 412 Top surface 500 Composite Laminated Assembly 508 Glass fiber layer 524 Top surface 600 flowcharts 700 aircraft 712 Propulsion System 714 Turbofan Engine 716 Wings 718 aircraft 720 Tail 722 Horizontal stabilizer 724 vertical stabilizer 800 freight section 802 Ceiling Panel 804 Side Panel 806 Floor Panel 812 Rainer 814 Raina 816 Raina 818 Raina

Claims

1. The steps include placing a first glass fiber layer (304) between a nonwoven carbon fiber layer (302) and a decorative layer (306), To form a composite laminated assembly (300), the steps include exposing the decorative layer (306), the first glass fiber layer (304), and the nonwoven carbon fiber layer (302) to one or more curing conditions. Methods that include...

2. The method according to claim 1, wherein the step of exposing the decorative layer (306), the first glass fiber layer (304), and the nonwoven carbon fiber layer (302) to one or more curing conditions changes the 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 steps include: placing a second glass fiber layer (508) on a nonwoven carbon fiber layer (302); To form the composite laminate assembly, the steps include: exposing the decorative layer (306), the first glass fiber layer (304), the nonwoven carbon fiber layer (302), and the second glass fiber layer (508) to one or more curing conditions; The method according to claim 1, further comprising:

4. The method according to claim 1, further comprising the step of applying heat or pressure to one or more nonwoven carbon fiber components (102A to 102C) in order 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 to 102C) are manufactured from recycled nonwoven carbon fiber material.

6. The first glass fiber layer (304) is manufactured from a thermoplastic material, and the method is The steps include: placing the first glass fiber layer (304) on one or more nonwoven carbon fiber components (102A to 102C); To form a subassembly including the nonwoven carbon fiber layer (302) and the first glass fiber layer (304), the steps include applying one or more of the heat and / or pressure to one or more of the nonwoven carbon fiber components (102A to 102C) and the first glass fiber layer (304), and The method according to claim 4, further comprising:

7. The method according to claim 1, wherein the first glass fiber layer (304) is manufactured from either a thermosetting glass fiber composite material or a thermoplastic glass fiber composite material.

8. The method according to claim 1, wherein the first glass fiber layer (304) is configured to be impregnated with a resin product.

9. The process involves machining the composite laminated assembly (300) to form a laminated product, The steps include installing the laminated product within an aircraft system (700) and The method according to claim 1, further comprising:

10. A composite laminated assembly (300), Nonwoven carbon fiber layer (302), A first glass fiber layer (304) having a bottom surface (314) that is operably bonded to the upper surface (312) of the nonwoven carbon fiber layer (302), A decorative layer (306) is operably bonded to the upper surface (316) of the first glass fiber layer (304) and Equipped with 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 in order to form a composite laminate assembly (300). Composite laminated assembly (300).

11. The nonwoven carbon fiber layer (302) further comprises a second glass fiber layer (508) which is operably bonded to the bottom surface (410), 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 in order to form the composite laminate assembly (500). The composite laminated assembly according to claim 10.

12. The composite laminate assembly according to claim 11, wherein the first glass fiber layer (304) and the second glass fiber layer (508) are configured to be impregnated with a resin product.

13. The composite laminate assembly according to claim 11, wherein the first glass fiber layer (304) and the second glass fiber layer (508) are manufactured from either a thermosetting glass fiber composite material or a thermoplastic glass fiber composite material.

14. The composite laminate assembly according to claim 10, wherein the nonwoven carbon fiber layer (302) is configured to be manufactured from recycled nonwoven carbon fiber material.

15. The first glass fiber layer (304) is made of a thermoplastic material, The first glass fiber layer (304) is configured to be arranged on one or more nonwoven carbon fiber components (102A to 102C), and the nonwoven carbon fiber layer (302) is formed from the one or more nonwoven carbon fiber components (102A to 102C). The first glass fiber layer (304) and the one or more nonwoven carbon fiber components are configured to be exposed to one or more of heat and / or pressure in order to form a subassembly comprising the nonwoven carbon fiber layer (302) and the first glass fiber layer (304). The composite laminated assembly according to claim 10.

16. The composite laminate assembly according to claim 10, further comprising an adhesive layer positioned between the top surface (316) of the first glass fiber layer (304) and the decorative layer (306) for bonding the decorative layer (306) to the top surface (316) of the first glass fiber layer (304) during exposure to one or more curing conditions.

17. A method for forming a composite laminated assembly (300), A step of placing the bottom surface (314) of a first glass fiber layer (304) facing the top surface (412) of a recycled carbon fiber layer (402), wherein the recycled carbon fiber layer (402) is made of a nonwoven carbon fiber material, and a step of The steps include: positioning the upper surface (524) of the second glass fiber layer (508) facing the bottom surface (410) of the recycled carbon fiber layer (402); The steps include placing a decorative layer (306) on the upper surface (316) of the first glass fiber layer (304), To form a composite laminated assembly (500), the steps include exposing the decorative layer (306), the first glass fiber layer (304), the recycled carbon fiber layer (402), and the second glass fiber layer (508) to one or more curing conditions. Methods that include...

18. The method according to claim 17, further comprising the step of applying one or more pressures and / or heat to the nonwoven carbon fiber material in order to form the recycled carbon fiber layer (402).

19. The first glass fiber layer (304) and the second glass fiber layer (508) are manufactured from a thermoplastic material, and the method is The steps include: arranging the first glass fiber layer (304) and the second glass fiber layer (508) on the nonwoven carbon fiber material; To form a subassembly comprising the recycled carbon fiber layer (402), the first glass fiber layer (304), and the second glass fiber layer (508), the steps of applying one or more of the heat and / or pressure to the first glass fiber layer (304), the second glass fiber layer (508), and the nonwoven carbon fiber material, The method according to claim 18, further comprising:

20. The steps include forming the composite laminated assembly (500) into a laminated product, The steps include installing the laminated product within an aircraft system (700) and The method according to claim 17, further comprising:

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