Abstract: Disclosed herein is a reinforced panel. The reinforced panel is produced by a process that comprises applying a reinforcing fiber material, comprising a first polymeric material, to only a portion of a panel sheet, comprising a second polymeric material. The process also comprises, after applying the reinforcing fiber material to the panel sheet, thermoforming both the second polymeric material of the panel sheet and the first polymeric material of the reinforcing fiber material. The thermoforming integrally couples the panel sheet with the reinforcing fiber material to produce the reinforced panel by fusion bonding the first polymeric material with the second polymeric material. The reinforced panel includes one or more reinforced portions, defined by the reinforcing fiber material, and one or more non-reinforced portions, defined between the reinforcing fiber material.

Abstract: A method for making a structural sandwich panel includes the steps of positioning a first and second thermoplastic skin elements in overlying relationship with respect to a heated male and heated female die molds respectively. A first pressure reduction is applied between the first thermoplastic skin element and the heated male die mold and a second pressure reduction is applied between the second thermoplastic and the heated female die mold. A core panel element is positioned between the heated male die mold and the heated female die mold wherein the core panel element has a first adhesive on a first side and has a second adhesive on a second opposing side. The male and female die molds are closed and exert a pressure onto the core panel element to secure the first and second thermoplastic skin elements to the core panel element and form the core panel element.

Abstract: An apparatus includes a matched die mold including a male die mold and a female die mold wherein the male die mold includes a first contoured surface and the female die mold includes a second contoured surface. The apparatus further includes a frame which defines an opening wherein the frame is positioned between the male die mold and the female die mold such that the frame is adapted to position a film layer across the opening and the opening is positioned in alignment with at least one of the first contoured surface and the second contoured surface.

Abstract: A method for making a structural sandwich panel includes the steps of positioning a first and second thermoplastic skin elements in overlying relationship with respect to a heated male and heated female die molds respectively. A first pressure reduction is applied between the first thermoplastic skin element and the heated male die mold and a second pressure reduction is applied between the second thermoplastic and the heated female die mold. A core panel element is positioned between the heated male die mold and the heated female die mold wherein the core panel element has a first adhesive on a first side and has a second adhesive on a second opposing side. The male and female die molds are closed and exert a pressure onto the core panel element to secure the first and second thermoplastic skin elements to the core panel element and form the core panel element.

Abstract: An apparatus includes a matched die mold including a male die mold and a female die mold wherein the male die mold includes a first contoured surface and the female die mold includes a second contoured surface. The apparatus further includes a frame which defines an opening wherein the frame is positioned between the male die mold and the female die mold such that the frame is adapted to position a film layer across the opening and the opening is positioned in alignment with at least one of the first contoured surface and the second contoured surface.

Abstract: A method of manufacturing a protective cover (24) for a component of a vehicle includes assembling multiple layers to form a charge (22). The charge (22) is formed within a mold (50) of the component to form a multi-contoured laminate (58). The protective cover (24) is separated from the multi-contoured laminate (58). A method of forming a down stream part structure or mold (167) for a component includes assembling multiple layers to form a charge (78). The charge (78) is formed within an original mold of the component to form a multi-contoured laminate (76). A splash is separated from the multi-contoured laminate (76). A protective cover, such as the cover (24), is for a vehicle component and includes a contour holding layer (36) and a protective laminate layer (34). The contour holding layer (36) and the protective laminate layer (34) are formed within a mold of the vehicle component to form the protective cover.

Abstract: A method of manufacturing a protective cover (24) for a component of a vehicle includes assembling multiple layers to form a charge (22). The charge (22) is formed within a mold (50) of the component to form a multi-contoured laminate (58). The protective cover (24) is separated from the multi-contoured laminate (58). A method of forming a down stream part structure or mold (167) for a component includes assembling multiple layers to form a charge (78). The charge (78) is formed within an original mold of the component to form a multi-contoured laminate (76). A splash is separated from the multi-contoured laminate (76). A protective cover, such as the cover (24), is for a vehicle component and includes a contour holding layer (36) and a protective laminate layer (34). The contour holding layer (36) and the protective laminate layer (34) are formed within a mold of the vehicle component to form the protective cover.

Abstract: A method of manufacturing a protective cover (24) for a component of a vehicle includes assembling multiple layers to form a charge (22). The charge (22) is formed within a mold (50) of the component to form a multi-contoured laminate (58). The protective cover (24) is separated from the multi-contoured laminate (58). A method of forming a down stream part structure or mold (167) for a component includes assembling multiple layers to form a charge (78). The charge (78) is formed within an original mold of the component to form a multi-contoured laminate (76). A splash is separated from the multi-contoured laminate (76). A protective cover, such as the cover (24), is for a vehicle component and includes a contour holding layer (36) and a protective laminate layer (34). The contour holding layer (36) and the protective laminate layer (34) are formed within a mold of the vehicle component to form the protective cover.

Abstract: A flight deck door for an aircraft that is both ballistic resistant and intruder proof. The flight deck door includes a laminated ballistic resistant material which can also provide intruder resistant properties. The ballistic resistant or armor material can be laminated onto a core to provide additional rigidity to the flight deck door. The core also increases the rigidity of the flight deck door and increases intruder resistance. Also sound dampening layers may be added to the door.