Abstract: A composite comprising adhered components and method of refurbishing such composites are described herein. The composite includes a first component, a second component, and the first component being adhered to the second component using an adhesive stack. The adhesive stack comprises a first adhesive-impregnated scrim layer disposed between the first component and the second component and a bulk adhesive layer disposed between the first component and the second component.

Abstract: A layer of adhesive is applied along a separation interface defined between a first surface of a first component and a second surface of a second component. A first portion of a pull cord is embedded into the adhesive layer along the separation interface and between the first and second surfaces. The first portion of the pull cord is positioned to enable the separation interface to be cleaved such that the first component is uncoupled from the second component. A second portion of the pull cord extends externally to the adhesive layer.

Abstract: A composite comprising adhered components and method of refurbishing such composites are described herein. The composite includes a first component, a second component, and the first component being adhered to the second component using an adhesive stack. The adhesive stack comprises a first adhesive-impregnated scrim layer disposed between the first component and the second component and a bulk adhesive layer disposed between the first component and the second component.

Abstract: A composite comprising adhered components and method of refurbishing such composites are described herein. The composite includes a first component, a second component, and the first component being adhered to the second component using an adhesive stack. The adhesive stack comprises a first adhesive-impregnated scrim layer disposed between the first component and the second component and a bulk adhesive layer disposed between the first component and the second component.

Abstract: A layer of adhesive is applied along a separation interface defined between a first surface of a first component and a second surface of a second component. A first portion of a pull cord is embedded into the adhesive layer along the separation interface and between the first and second surfaces. The first portion of the pull cord is positioned to enable the separation interface to be cleaved such that the first component is uncoupled from the second component. A second portion of the pull cord extends externally to the adhesive layer.

Abstract: A window panel adapted for installation relative to a structure. The panel includes a single piece of generally transparent injection-molded material configured to span one or more openings in the structure. The panel has panel attachment inserts for attaching the panel relative to the structure. The inserts are embedded in the material alongside at least one edge of the panel. The panel has a curvature that essentially continues a curvature of the structure surrounding the opening(s) when the panel is installed relative to the structure. This panel can be single-pane and can provide an essentially continuous window along an aircraft fuselage.

Abstract: A window panel adapted for installation relative to a structure. The panel includes a single piece of generally transparent injection-molded material configured to span one or more openings in the structure. The panel has panel attachment inserts for attaching the panel relative to the structure. The inserts are embedded in the material alongside at least one edge of the panel. The panel has a curvature that essentially continues a curvature of the structure surrounding the opening(s) when the panel is installed relative to the structure. This panel can be single-pane and can provide an essentially continuous window along an aircraft fuselage.

Abstract: A window panel adapted for installation relative to a structure. The panel includes a single piece of generally transparent injection-molded material configured to span one or more openings in the structure. The panel has panel attachment inserts for attaching the panel relative to the structure. The inserts are embedded in the material alongside at least one edge of the panel. The panel has a curvature that essentially continues a curvature of the structure surrounding the opening(s) when the panel is installed relative to the structure. This panel can be single-pane and can provide an essentially continuous window along an aircraft fuselage.

Abstract: A structural panel includes a frame having one or more attachment members. A material injection-molded onto at least a portion of the frame fills one or more openings at least partly defined by the frame and defines at least a portion of a shape of the panel. The attachment member(s) are at least partially embedded in the injection-molded material for attaching the panel relative to the structure. Because attachment members can be embedded in this panel, little if any post-processing is needed to install the panel.

Abstract: A method of installing a window panel in an aircraft. The method includes connecting upper and lower ends of the window panel with upper and lower longerons of the aircraft, and connecting a side end of the window panel with a hoop frame of the aircraft. This method makes it possible to eliminate heavy window support structures and to provide continuous hoop frame support members in an aircraft fuselage.

Abstract: A method for vacuum assisted resin transfer molding a composite structure including fibers at least partially surrounded by resin using a mold including a tool having a surface shaped to correspond to the composite structure and an inflatable bladder for forcing the composite structure against the tool. A resin inlet is connected to a resin source for introducing resin into a mold cavity at least partially defined by the tool surface and the bladder and a vacuum port spaced from the resin inlet. The method includes the steps of opening the mold cavity, loading fibers into the open mold cavity, closing the loaded mold cavity, introducing resin through the resin inlet into the closed mold cavity loaded with fibers, and pulling a vacuum at the resin inlet and the vacuum port to draw excess resin from the structure prior to curing thereof.

Abstract: An injection molded windshield is provided for a vehicle. The injection molded acrylic or polycarbonate windshield enables vehicle shape design flexibility while achieving lower aerodynamic drag. The injection molded windshields offer additional benefits for the crew by increasing visibility area with larger windshields while reducing aero noise. The vehicle includes a body and an injection molded window attached to the body. The injection molded windshield is shaped to conform to the fuselage. The injection molded windshield is formed of at least one of an injection molded acrylic or polycarbonate material. The injection molded windshield is impact and ballistic tolerant.

Abstract: A method for forming complexly shaped composite laminate assemblies. A pair of dry fiber preforms are placed on a tool with a thin film adhesive layer therebetween. A vacuum bag encloses the preforms and the adhesive layer. The preforms are heated to a temperature sufficient to cause the adhesive to become viscous and to wet several plys of each of the preforms. The preforms are then allowed to cool slightly before resin is infused via a vacuum source through each of the preforms to thoroughly wet each of the preforms. The resulting joint formed at the bond line of the two preforms is stronger than what would be formed simply by adhering two otherwise completely formed preforms together because the dry fiber preforms, in connection with the heating of the preforms, allow wetting of several plys of each of the preforms at the joint area, rather than just the surface ply of each preform.

Abstract: Systems and methods for providing rain and ice removal on a windshield are. provided. The system may be implemented on a vehicle, such as an aircraft. In one embodiment, a system includes an injection molded windshield and a frame coupled to the injection-molded windshield and to the vehicle. The frame includes a channel that directs at least one of air or fluid onto an exterior surface of the windshield. The frame includes one or more one-way check valves. A fluid pump pumps fluid through the channel and onto the windshield. A reservoir stores de-icing fluid that is retrieved by the fluid pump. Air sources pump air through the channel and onto the one or more windshields. A controlling device controls the fluid pump or the air sources.

Abstract: An apparatus and method for latching a canopy to a vehicle, such as an aircraft, that avoids plastic creep and crazing due to concentrated loads is provided. The apparatus includes first attachment components that are at least partially embedded within an injection-molded canopy and second attachment components that are connected to the canopy rail for attaching to the one or more first attachment components and thereby attaching the canopy to the canopy rail.

Abstract: A window panel adapted for installation relative to a structure. The panel includes a single piece of generally transparent injection-molded material configured to span one or more openings in the structure. The panel has panel attachment inserts for attaching the panel relative to the structure. The inserts are embedded in the material alongside at least one edge of the panel. The panel has a curvature that essentially continues a curvature of the structure surrounding the opening(s) when the panel is installed relative to the structure. This panel can be single-pane and can provide an essentially continuous window along an aircraft fuselage.

Abstract: A method of installing a window panel in an aircraft. The method includes connecting upper and lower ends of the window panel with upper and lower longerons of the aircraft, and connecting a side end of the window panel with a hoop frame of the aircraft. This method makes it possible to eliminate heavy window support structures and to provide continuous hoop frame support members in an aircraft fuselage.

Abstract: A structural panel includes a frame having one or more attachment members. A material injection-molded onto at least a portion of the frame fills one or more openings at least partly defined by the frame and defines at least a portion of a shape of the panel. The attachment member(s) are at least partially embedded in the injection-molded material for attaching the panel relative to the structure. Because attachment members can be embedded in this panel, little if any post-processing is needed to install the panel.

Abstract: An apparatus and method for latching a canopy to a vehicle, such as an aircraft, that avoids plastic creep and crazing due to concentrated loads is provided. The apparatus includes first attachment components that are at least partially embedded within an injection-molded canopy and second attachment components that are connected to the canopy rail for attaching to the one or more first attachment components and thereby attaching the canopy to the canopy rail.

Abstract: Door systems and methods of making a door that provide added security in a vehicle, such as a commercial aircraft. An example door system includes a door, a source of pressurized fluid, and a frame. The door includes an injection-molded polycarbonate base, a plurality of hinge inserts embedded within the injection-molded polycarbonate base, and an inflatable seal. The source inflates the inflatable seal. The frame includes hinges that attach to the plurality of hinge inserts.