Abstract: Continuous compression molding machines (CCMMs) and methods of continuous compression molding a consolidated thermoplastic matrix composite material are disclosed herein. The CCMMs include a mold, a heat zone heating structure, a consolidation zone heating structure, and a stress relaxation zone heating structure. The CCMMs also include a press structure, a demold structure, and a supply structure. The methods include providing a thermoplastic matrix composite material (TMCM) that includes a thermoplastic material to a CCMM. During the providing, the methods also include heating the TMCM within a heat zone of the CCMM, cooling and consolidating the TMCM within a consolidation zone of the CCMM, relaxing stress within the TMCM within a stress relaxation zone of the CCMM, demolding the TMCM within a demold zone of the CCMM at a mold temperature that is greater than a glass transition temperature of the thermoplastic material, and periodically compressing the TMCM.

Abstract: A composite skin is attached to an underlying structure by fasteners that are countersunk into the structure. The composite skin comprises a thermoplastic material that has been melted and formed into a countersink in the structure using a heated tool.

Abstract: Continuous compression molding machines (CCMMs) and methods of continuous compression molding a consolidated thermoplastic matrix composite material are disclosed herein. The CCMMs include a mold, a heat zone heating structure, a consolidation zone heating structure, and a stress relaxation zone heating structure. The CCMMs also include a press structure, a demold structure, and a supply structure. The methods include providing a thermoplastic matrix composite material (TMCM) that includes a thermoplastic material to a CCMM. During the providing, the methods also include heating the TMCM within a heat zone of the CCMM, cooling and consolidating the TMCM within a consolidation zone of the CCMM, relaxing stress within the TMCM within a stress relaxation zone of the CCMM, demolding the TMCM within a demold zone of the CCMM at a mold temperature that is greater than a glass transition temperature of the thermoplastic material, and periodically compressing the TMCM.

Abstract: Continuous compression molding machines (CCMMs) and methods of continuous compression molding a consolidated thermoplastic matrix composite material are disclosed herein. The CCMMs include a mold, a heat zone heating structure, a consolidation zone heating structure, and a stress relaxation zone heating structure. The CCMMs also include a press structure, a demold structure, and a supply structure. The methods include providing a thermoplastic matrix composite material (TMCM) that includes a thermoplastic material to a CCMM. During the providing, the methods also include heating the TMCM within a heat zone of the CCMM, cooling and consolidating the TMCM within a consolidation zone of the CCMM, relaxing stress within the TMCM within a stress relaxation zone of the CCMM, demolding the TMCM within a demold zone of the CCMM at a mold temperature that is greater than a glass transition temperature of the thermoplastic material, and periodically compressing the TMCM.

Abstract: A method and structure for processing a plurality of prepreg sheets includes a conveyor assembly having a first conveyor, a second conveyor, and a processing zone positioned between the first and second conveyors. In an implementation, a plurality of prepreg sheets are advanced from a plurality of material supply creels into the processing zone by a first conveyor and a second conveyor turning in opposite directions. Within the processing zone, a compressive pressure is applied to the prepreg sheets by first pressure plates attached to first conveyor and second pressure plates attached to the second conveyor. A thermoplastic within the prepreg sheets is melted within the processing zone by a heater to consolidate the prepreg sheets into a consolidated laminate.

Abstract: An assembly to manufacture a roll of prepreg material. The assembly includes a moving system for picking a sheet of prepreg material from a stack of sheets and moving the sheet along a feed path. An alignment system aligns a leading edge of the sheets with a trailing edge of a roll of the prepreg material. A welding system connects the sheet to the roll.

Abstract: A method and structure for processing a plurality of prepreg sheets includes a conveyor assembly having a first conveyor, a second conveyor, and a processing zone positioned between the first and second conveyors. In an implementation, a plurality of prepreg sheets are advanced from a plurality of material supply creels into the processing zone by a first conveyor and a second conveyor turning in opposite directions. Within the processing zone, a compressive pressure is applied to the prepreg sheets by first pressure plates attached to first conveyor and second pressure plates attached to the second conveyor. A thermoplastic within the prepreg sheets is melted within the processing zone by a heater to consolidate the prepreg sheets into a consolidated laminate.

Abstract: An assembly to manufacture a roll of prepreg material. The assembly includes a moving system for picking a sheet of prepreg material from a stack of sheets and moving the sheet along a feed path. An alignment system aligns a leading edge of the sheets with a trailing edge of a roll of the prepreg material. A welding system connects the sheet to the roll.

Abstract: A cover for an empty rail missile launcher that can be used in flight. The cover is shaped to reflect radar signals transmitted by a radar transmitter away from the radar transmitter to reduce detectibility by radar. The cover may also be coated with radar absorbent material to reduce detectibility by radar. Hangers are used to mount the cover to the rail missile launcher. The cover is provided with a grounding mechanism to dissipate precipitation static. A restraint mechanism is provided to prevent the cover from inadvertently sliding off the rail missile launcher.

Abstract: A cover for an empty rail missile launcher that can be used in flight. The cover is shaped to reflect radar signals transmitted by a radar transmitter away from the radar transmitter to reduce detectibility by radar. The cover may also be coated with radar absorbent material to reduce detectibility by radar. Hangers are used to mount the cover to the rail missile launcher. The cover is provided with a grounding mechanism to dissipate precipitation static. A restraint mechanism is provided to prevent the cover from inadvertently sliding off the rail missile launcher.