Abstract: An embedded-object composite product including a solid-state mass of PET, an object embedded in the PET material mass, and a zone possessing a continuous material-density gradient in the PET material mass, with more-dense PET material residing closely adjacent the embedded object, and less-dense PET material residing more distant from that object. This product is produced effectively by non-destructively heating the PET mass from its solid state to allow it to flow as a liquid, by then pressing the object into the heated PET mass to perform object embedment and to create a declining PET-material density in the region adjacent, and progressing from adjacent, the embedded object, and by thereafter cooling the mass to re-solidify it.

Abstract: A layered panel structure including first and second layers formed, respectively, of (a) non-thermoformable, and (b) thermoformable, fiber-strand-reinforced resin, materials, having therebetween a bonding interface formed by resin drawn from the second layer.

Abstract: A layered panel structure including first and second layers formed, respectively, of (a) non-thermoformable, and (b) thermoformable, fibre-strand-reinforced resin, materials, having therebetween a bonding interface formed by resin drawn from the second layer.

Abstract: A method of forming a layered, generally planar panel structure including the steps of (a) utilizing applied heat and pressure, causing a melt of resin present in a thermoformable material layer to flow toward and into an adjacent non-thermoformable material layer, and (b) by such utilizing and causing, forming a thermal-compression, mechanical, inter-material-transition bond between the layers.

Abstract: A layered panel structure featuring a first layer formed of non-thermoformable material, having opposite faces, a thickness T as measured between its opposite faces, and an effective layer density d, and a second layer formed of thermoformable material having opposite faces, with one face in the second layer being thermally bonded to one face in the first layer, and with the second layer having a thickness t, as measured between its opposite faces which is smaller than T, and an effective layer density D which is greater than d. The thermal bond between the layers is formed, during thermoforming of the panel structure, by a melt and flow of resin contained in the thermoformable layer material.

Abstract: A generally planar composite panel structure including (a) a stratified, generally planar main body core having perimetral edges, and spaced, generally planar, outwardly facing facial expanses extending substantially to such edges, and (b) in a stacked arrangement within the core, intermediate the mentioned facial expanses, at least one high-density, generally planar, fibre-reinforced layer structure bracketed by a pair of low-density, generally planar layer structures, each of which layer structures extends substantially to the core's perimetral edges.

Abstract: A heat and pressure method for creating, from plural, unconsolidated, composite, heat-and-pressure-formable, compressible starter materials having an initial, combined-material starter density D1 and starter thickness T1, a composite-material structural panel having a combined-material density D2 and thickness T2, where D1 is less than D2 and T1 is greater than T2. The method includes the steps of (a) selecting starter materials having known, respective, nominal density and thickness characteristics, (b) creating an unconsolidated stack of such materials to have a combined-material density D1 and thickness T1, (c) applying heat and pressure to that stack, and (d) thereby consolidating and compressing the stack to produce the desired, finished structural panel possessing an overall, combined-material density D2 and thickness T2.

Abstract: A heat-formation method for creating a composite, layered structural panel which possesses at least one selected area of elevated densification and reinforcement including (a) providing a pre-heat-formed, layered expanse of compressible, heat-formable, composite sheet material having a reception face and a starter thickness T1, (b) establishing a pre-formation assembly of materials by placing on a selected area of the reception face an already heat-formed and densified island of essentially the same layered composite sheet material which defines the expanse, with such island having a thickness T2 which is less than T1, (c) employing heat and pressure, consolidating and compressing the expanse and the island to form, in an embedment region in the panel, an embedded-island, finished panel having an allover uniform thickness T3 which is less than T1, and wherein the region associated with the island has an embedment thickness T4 which is equal to or less than T2, and an effective density which is elevated in rel

Abstract: An embedded-object composite product including a solid-state mass of PET, an object embedded in the PET material mass, and a zone possessing a continuous material-density gradient in the PET material mass, with more-dense PET material residing closely adjacent the embedded object, and less-dense PET material residing more distant from that object. This product is produced effectively by non-destructively heating the PET mass from its solid state to allow it to flow as a liquid, by then pressing the object into the heated PET mass to perform object embedment and to create a declining PET-material density in the region adjacent, and progressing from adjacent, the embedded object, and by thereafter cooling the mass to re-solidify it.

Abstract: A method utilizing elevated temperature and applied pressure to form a layered, composite-material structural panel including (a) establishing a layer-stack assembly in the form of a pre-consolidation expanse having everywhere an independent, location-specific, pre-consolidation local thickness T, and including at least a pair of confronting, thermoformable polypropylene-based layers, (b) heating the assembly to a thermoform temperature, (c) compressing the heated assembly to create a thermal bond between the two layers, and to consolidate the assembly into a post-consolidation expanse having everywhere an independent, location-specific, post-consolidation, local thickness t which is less than the respective, associated, pre-consolidation local thickness T, and (d) cooling the consolidated assembly to a sub-thermoform temperature to stabilize it in its consolidated condition.

Abstract: Composite panel structure including a pair of spaced, generally parallel-planar, fibre-reinforced, facial cladding sheets, and, disposed between and thermally bonded to these sheets, core structure including interleaved, generally side-by-side-parallel, elongate, low-density core elements, and elongate, higher-density, fibre-reinforced frame elements. Each frame element includes a pair of generally orthogonally intersecting, planar facial expanses, one of which is bonded to an adjacent core element, and the other of which is bonded to one of the cladding sheets.

Abstract: A generally planar composite panel structure including (a) a generally planar main body having perimetral edges, and spaced, generally planar, outwardly facing facial expanses extending substantially to such edges, and (b) within the main body, intermediate the mentioned facial expanses, at least one high-density, generally planar, fibre-reinforced layer structure bracketed by a pair of low-density, generally planar layer structures, each of which layer structures extends substantially to the main-body's perimetral edges.

Abstract: An embedded-object composite product including a solid-state mass of PET, an object embedded in the PET material mass, and a zone possessing a continuous material-density gradient in the PET material mass, with more-dense PET material residing closely adjacent the embedded object, and less-dense PET material residing more distant from that object. This product is produced effectively by non-destructively heating the PET mass from its solid state to allow it to flow as a liquid, by then pressing the object into the heated PET mass to perform object embedment and to create a declining PET-material density in the region adjacent, and progressing from adjacent, the embedded object, and by thereafter cooling the mass to re-solidify it.

Abstract: A layered panel structure featuring a first layer formed of non-thermoformable material, having opposite faces, a thickness T as measured between its opposite faces, and an effective layer density d, and a second layer formed of thermoformable material having opposite faces, with one face in the second layer being thermally bonded to one face in the first layer, and with the second layer having a thickness t, as measured between its opposite faces which is smaller than T, and an effective layer density D which is greater than d. The thermal bond between the layers is formed, during thermoforming of the panel structure, by a melt and flow of resin contained in the thermoformable layer material.

Abstract: A method utilizing elevated temperature and applied pressure to form a layered, composite-material structural panel including (a) establishing a layer-stack assembly in the form of a pre-consolidation expanse having everywhere an independent, location-specific, pre-consolidation local thickness T, and including at least a pair of confronting, different-thermoformable-material layers, (b) heating the assembly to a thermoform temperature, (c) compressing the heated assembly to create a thermal bond between the two layers, and to consolidate the assembly into a post-consolidation expanse having everywhere an independent, location-specific, post-consolidation, local thickness t which is less than the respective, associated, pre-consolidation local thickness T, and (d) cooling the consolidated assembly to a sub-thermoform temperature to stabilize it in its consolidated condition.

Abstract: An armor panel for defeating a projectile strike including (a) a substantially planar core structure having spaced, generally parallel-planar strike and opposite faces, and elongate, circumsurrounding edge structure extending generally normally between these faces to define a perimeter for the core structure, (b) stranded core-wrap structure substantially fully enveloping the core structure, and possessing elongate, tension-load-bearing (TLB) strands which extend at angles relative to one another across the mentioned faces, and substantially parallel to one another in a distribution along the perimeter defined by the edge structure, and (c) a high-elastomeric coating which is distributed over at least those portions of the core-wrap structure which are disposed adjacent the strike face and the edge structure.