Patent Description:
Generally speaking, aircraft include an aircraft skin that encloses or surrounds an interior volume, which may be utilized to carry the flight crew, passengers, and cargo, as well as various aircraft systems and components. Typically, aircraft include aircraft windows that permit visual access from the interior volume to the surroundings of the aircraft. An aircraft window usually is formed with a window aperture that extends through the aircraft skin. A typical aircraft window includes a window assembly having a window frame that is supported on an interior or inside surface of the aircraft skin about the window aperture and a window pane that is supported on and positioned by the window frame to extend across at least a substantial portion of the window aperture. The window frame typically includes a flange portion that is supported on the aircraft skin and a lip portion extending inwardly and out of plane from the flange portion that forms a support surface for the window pane. The window assembly also may include a window pane retention system that holds the window pane against the window frame.

In recent years, the window frames of aircraft window assemblies increasingly are being formed from continuous fiber reinforced composites due to their superior weight and mechanical properties relative to metal alloys. Existing window frames formed from continuous fiber reinforced composites typically have complex doubly-curved geometry, with a tightly curved perimeter that follows the window aperture and two bends with tight radii in the cross-section, that orient and position the flange and lip portions to support the window pane at the correct position relative to the aircraft skin and window aperture. The tight radii of curvature required in these structures can cause wrinkling of the reinforcing fibers during manufacture, which can affect the strength of the window frame. Additionally, these structures frequently require additional parts in window pane retention systems as compared to conventional alloy-based window frames. Thus, a need exists for improved aircraft window assemblies having continuous fiber reinforced composite window frames that may include improved strength characteristics and/or require fewer parts.

Document <CIT>, according to its abstract, states a system for constructing a composite structure includes a braiding machine, a winding tool and a forming machine. The composite structure is constructed of a wound tubular braiding. The wound tubular braiding is constructed of a biaxial or triaxial tubular braid of unidirectional tape.

Document <CIT>, according to its abstract, states a window frame assembly for an aircraft includes a window frame of composite material, adapted for attachment in a window opening of an aircraft, having an outer flange with an exterior surface and an interior surface, a metal erosion shield attached to the exterior surface of the outer flange, and a polymer adapter ring attached to the interior surface of the outer flange. The window frame has a substantially constant thickness, and the erosion shield has a substantially constant cross-sectional shape. The adapter ring has a sloped engagement surface configured for supporting a window pane assembly.

Document <CIT>, according to its abstract, states a component comprises a first part and a second part, wherein said second part is in contact with said first part, wherein: (i) said first part comprises a first polymer which is semi-crystalline and includes phenylene moieties, carbonyl moieties and ether moieties; (ii) said second part comprises a second polymer which is semi-crystalline and includes phenylene moieties, carbonyl moieties and ether moieties; (iii) the melting temperature (Tm) of the second polymer is less than the melting temperature (Tm) of the first polymer. In a preferred embodiment, said first polymer is polyetheretherketone and said second polymer is a copolymer having a repeat unit of formula VIII and a repeat unit of formula IX.

The present disclosure relates to aircraft window assemblies and methods of forming window frames. The aircraft window assemblies comprise a window frame configured to support a window pane on an aircraft skin around a circumference of a window aperture defined in the aircraft skin and to align the window pane with the window aperture, wherein the window frame comprises a base formed of a continuous fiber reinforced thermoplastic composite, wherein the base is ring-shaped and defines a central aperture, and wherein the base comprises a circumferential flange portion defining a radial exterior of the base and configured to support the base on the aircraft skin surrounding the window aperture; a skirt portion extending radially inwardly from the circumferential flange portion and surrounding the central aperture, wherein the skirt portion is non-planar with the circumferential flange portion and comprises a support surface for supporting the window pane of the aircraft window assembly; and at least one overmolded feature molded to the base; wherein the aircraft window assembly further comprises a plurality of window frame fastener bores extending through and spaced-apart around the circumferential flange portion and configured to receive a respective plurality of window frame fasteners to retain the window frame to the aircraft skin, wherein the at least one overmolded feature comprises a plurality of overmolded protrusions, wherein each overmolded protrusion is molded atop a window frame fastener bore of the plurality of window frame fastener bores, and wherein each overmolded protrusion is configured to receive a window frame fastener receiver, and wherein each window frame fastener receiver is configured to receive and engage a window frame fastener of the plurality of window frame fasteners.

Further, there is provided a method according to claim <NUM> comprising forming the window frame, which comprise stamp-forming the base of the window frame from a sheet of continuous fiber reinforced thermoplastic composite and overmolding the at least one overmolded feature to the base.

<FIG> provide examples of aircraft window assemblies <NUM>, aircraft <NUM> including aircraft window assemblies <NUM>, window frames <NUM> of aircraft window assemblies <NUM>, and methods <NUM> of forming window frames <NUM> according to the present disclosure. Elements that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of <FIG>, and these elements may not be discussed in detail herein with reference to each of <FIG>. Similarly, all elements may not be labeled in each of <FIG>, but reference numerals associated therewith may be utilized herein for consistency. Elements, components, and/or features that are discussed herein with reference to one or more of <FIG> may be comprised in and/or utilized with any of <FIG> without departing from the scope of the present disclosure.

Generally, in the figures, elements that are likely to be comprised in a given example are illustrated in solid lines, while elements that are optional to a given example are illustrated in dashed lines. However, elements that are illustrated in solid lines are not essential to all examples of the present disclosure, and an element shown in solid lines may be omitted from a particular example without departing from the scope of the present disclosure. Additionally, in schematic <FIG> and <FIG>, virtual features, such as axes, dimensions, etc. that may be defined by window assemblies, aircraft, and/or window frames according to the present disclosure are indicated in dash-dot lines, and these virtual features may or may not be optional to the illustrated embodiment. Also in schematic <FIG> and <FIG>, dotted lines are utilized to indicate structure, elements, regions, and/or spaces that may be environment to and/or utilized in conjunction with aircraft window assemblies <NUM>.

<FIG> is an illustration of examples of aircraft <NUM> that comprise a plurality of aircraft window assemblies <NUM>, according to the present disclosure. Examples of aircraft window assemblies <NUM> are illustrated in <FIG> and discussed in more detail herein with reference thereto. Aircraft <NUM> comprise an aircraft skin <NUM> that surrounds an internal volume that is referred to herein as an aircraft interior <NUM>. Aircraft skin <NUM> at least partially separates aircraft interior <NUM> from a region <NUM> exterior to aircraft <NUM>. Aircraft <NUM> may comprise a fuselage <NUM> that defines, or surrounds at least a portion of aircraft interior <NUM>. Aircraft <NUM> also may comprise at least one wing <NUM>, a tail assembly <NUM>, and at least one engine <NUM>. Each wing <NUM> may be operatively attached to and/or extend from fuselage <NUM>. Engine <NUM> also may be operatively attached to fuselage <NUM> such as via a corresponding wing <NUM>. Tail assembly <NUM> may be operatively attached to and/or may be at least partially defined by fuselage <NUM>. Tail assembly <NUM> may comprise at least one vertical stabilizer <NUM> and/or at least one horizontal stabilizer <NUM>.

Aircraft <NUM> further comprises a plurality of aircraft windows <NUM>. Each aircraft window is formed with a window aperture <NUM> that is defined in aircraft skin <NUM> and forms an opening between aircraft interior <NUM> and region <NUM> exterior to aircraft <NUM>. A plurality of, and optionally each of, aircraft windows <NUM> comprises aircraft window assembly <NUM>. That said, in some examples of aircraft <NUM>, one or more aircraft windows <NUM> comprise an aircraft window assembly that is different from aircraft window assemblies <NUM> according to the present disclosure.

Each aircraft window assembly <NUM> is operatively attached to aircraft skin <NUM> around a corresponding window aperture <NUM>. Each aircraft window assembly <NUM> is configured span the respective window aperture <NUM> to partition, or sealably partition, aircraft interior <NUM> from region <NUM> exterior to aircraft <NUM>. Thus, aircraft skin <NUM> and aircraft window assembly(s) <NUM> may be described as collectively being configured to completely separate, or sealably separate, aircraft interior <NUM> from region <NUM> exteriorto aircraft <NUM>. In some examples, at least some of, and optionally all of, aircraft windows <NUM> are disposed along fuselage <NUM>.

Aircraft <NUM> may comprise any suitable type of aircraft with examples including private aircraft, commercial aircraft, passenger aircraft, military aircraft, jetliners, wide-body aircraft, and/or narrow body aircraft. While <FIG> shows an example in which aircraft <NUM> is a fixed wing aircraft, aircraft window assemblies <NUM> may be comprised in and/or utilized with any other suitable type of aircraft such as rotor craft and/or helicopters.

<FIG> is a schematic representation showing examples of aircraft window assemblies <NUM> according to the present disclosure. <FIG> is a schematic cross-sectional view taken along line <NUM>-<NUM> of <FIG> and showing examples of aircraft window assemblies <NUM> that comprise an overmolded aero filler <NUM> and an overmolded protruding rib <NUM>, as discussed in more detail herein. However, as shown in <FIG> overmolded aero filler <NUM> and overmolded protruding rib <NUM> are not required in all examples of aircraft window assemblies <NUM> according to the present disclosure.

As shown in the examples of <FIG> and <FIG>, aircraft window assemblies <NUM> comprise a window frame <NUM> configured to support a window pane <NUM> on aircraft skin <NUM> about window aperture <NUM> defined in aircraft skin <NUM>. Window frame <NUM> comprises a base <NUM> formed of a continuous fiber reinforced thermoplastic composite and at least one overmolded feature <NUM> molded to base <NUM>. Base <NUM> is ring-shaped and defines a central aperture <NUM>. Base <NUM> comprises a circumferential flange portion <NUM> and a skirt portion <NUM>. Circumferential flange portion <NUM> defines a radial exterior of base <NUM> and is configured to support base <NUM> on a portion of aircraft skin <NUM> that surrounds window aperture <NUM>. Skirt portion <NUM> extends radially inwardly from circumferential flange portion <NUM> and surrounds central aperture <NUM>. Skirt portion <NUM> is non-planar with circumferential flange portion <NUM> and comprises a support surface <NUM> for supporting window pane <NUM>. Window pane <NUM> is dimensioned and shaped to extend across central aperture <NUM>, to be seated on support surface <NUM>, and to provide a partition across central aperture <NUM>. Skirt portion <NUM> additionally or alternatively may be referred to herein as frame lip <NUM>.

Central aperture <NUM> may have any suitable shape, such as a circular, ovular, elliptical, and/or rounded rectangular shape. Window pane <NUM> also may have any suitable shape, such as a circular, ovular, elliptical, and/or rounded rectangular shape that may correspond to, or at least substantially correspond to, that of central aperture <NUM>. Window pane <NUM> may comprise a pane exterior surface <NUM> that is configured to face region <NUM> exterior to aircraft <NUM> and a pane interior surface <NUM> that is configured to face aircraft interior <NUM>. In some examples, window pane <NUM> is curved such that pane interior surface <NUM> is concave and pane exterior surface <NUM> is convex.

In some examples, window frame <NUM>, and/or base <NUM> thereof, comprises an interior face <NUM> that is configured to face aircraft interior <NUM> and an exterior face <NUM> that is configured to face region <NUM> exterior to aircraft <NUM>. In <FIG>, interior face <NUM> of window frame <NUM> illustrated above the schematic cut line, and exterior face <NUM> of window frame <NUM> is illustrated below the schematic cut line. For purposes of illustration, aircraft skin <NUM> is omitted from the portion of <FIG> below the schematic cut line. In some examples, exterior face <NUM> of circumferential flange portion <NUM> is configured to operatively contact aircraft skin <NUM> and support aircraft window assembly <NUM> on aircraft skin <NUM>. More specifically, in some examples, aircraft skin <NUM> comprises a skin exterior surface <NUM> that faces region <NUM> exterior to aircraft <NUM> and a skin interior surface <NUM> that is opposed to skin exterior surface <NUM> and that faces aircraft interior <NUM>. In some such examples, exterior face <NUM> of circumferential flange portion <NUM> is configured to operatively contact skin interior surface <NUM>. As used herein, "operatively contact" does not require direct physical engagement, as a gasket, O-ring, adhesive, or other material may be positioned directly between exterior face <NUM> of circumferential flange portion <NUM> and skin interior surface <NUM>. In some examples, support surface <NUM> is included in interior face <NUM> of skirt portion <NUM>. In other words, window pane <NUM> may be supported on interior face <NUM> of skirt portion <NUM>.

As shown in <FIG>, aircraft window assembly <NUM> may define a central axis <NUM> that extends through the geometric or symmetrical center of central aperture <NUM> and generally along a direction between interior face <NUM> and exterior face <NUM>. The distance of a given portion, surface, feature, and/or region of window frame <NUM> from central axis <NUM> may be defined herein with a circumferential radius <NUM> that originates at central axis and extends normal to central axis <NUM>. In some examples, the distance of given portion, surface, feature, and/or region of window frame <NUM> from central axis <NUM> along circumferential radius <NUM> varies with respect to rotation about central axis <NUM>. In view of the above, circumferential flange portion <NUM> being discussed herein as defining the radial exterior of base <NUM> refers to circumferential flange portion <NUM> being the portion of base <NUM> that extends with the largest average circumferential radius <NUM> from central axis. Also as discussed herein, a first portion, surface, feature, and/or region of window frame <NUM> may be described as being inside of a second portion, surface, feature, and/or region of window frame <NUM> when it is positioned closer to central axis <NUM>. In the same situation, the second portion, surface, feature, and/or region of window frame <NUM> may be described as being outside of the first portion region, surface, feature, and/or region.

Central axis <NUM> additionally or alternatively may be defined as extending normal to a plane along which circumferential flange portion <NUM> extends. More specifically, circumferential flange portion <NUM> may be regarded as having a planar configuration for the purpose of discussing relative dimensions of aircraft window assembly <NUM> and/or positionality therein. However, as illustrated in <FIG>, aircraft skin <NUM> is curved in one or more directions such as to surround aircraft interior <NUM>. With this in mind, in some examples, circumferential flange portion <NUM> and/or window frame <NUM> possess a global curvature that is configured to match, or to be at least substantially equivalent to, the local curvature of aircraft skin <NUM> surrounding window aperture <NUM>.

In other words, while circumferential flange portion <NUM> may be discussed herein as having a planar configuration with regard to the relative dimensions of aircraft window assembly <NUM>, in some examples, circumferential flange portion <NUM> is, in reality, curved to match the local curvature of aircraft skin <NUM>, and/or skin interior surface <NUM> thereof, about window aperture <NUM>. The local curvature of aircraft skin <NUM>, and correspondingly the global curvature of circumferential flange portion <NUM> and/or window frame <NUM>, may vary depending upon the size, shape, and/or type of aircraft <NUM> and/or the location that aircraft window assembly <NUM> is installed along aircraft skin <NUM>. In some more specific examples, exterior face <NUM> of window frame <NUM>, and/or base <NUM> thereof, comprises a convex global curvature and interior face <NUM> of window frame <NUM>, and/or base <NUM> thereof, comprises a concave global curvature.

In view of the above, skirt portion <NUM> being described herein as "non-planar" with circumferential flange portion <NUM> is not intended to indicate that circumferential flange portion <NUM> comprises a planar configuration, but instead that skirt portion <NUM> diverges from circumferential flange portion <NUM> with circumferential flange portion <NUM> and skirt portion <NUM>, each optionally being shaped with the global curvature. In other words, the relative dimensions of aircraft window assembly <NUM> discussed herein with regard to circumferential flange portion <NUM> having a planar configuration simply may be mapped onto the global curvature of window frame <NUM>, and/or base <NUM>, and this global curvature may be selected based upon the size of aircraft window assembly <NUM>, the type and/or size of aircraft <NUM>, and/or the location of window assembly within aircraft <NUM>.

As mentioned, base <NUM> is formed of a continuous fiber reinforced thermoplastic composite. In some examples, the continuous fiber reinforced thermoplastic composite comprises a thermoplastic matrix material and at least one layer of, and optionally a plurality of layers of, continuous reinforcing fibers embedded in the thermoplastic matrix material. In some examples, the continuous reinforcing fibers of a given layer are arranged in a unidirectional relationship. Additionally or alternatively, in some examples the continuous reinforcing fibers of given layer are woven into a fabric. The thermoplastic matrix material comprises at least one, and optionally a mixture of more than one, thermoplastic polymer that binds together with the continuous reinforcing fibers. Examples of suitable thermoplastic polymers for forming the thermoplastic matrix material comprise low-melt polyaryletherketone (PAEK) polymers, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), and/or polyetherketoneketone (PEKK). Examples of suitable continuous reinforcing fibers comprise carbon fibers, glass fibers, boron fibers, ultra-high molecular weight polyethylene fibers, aramid fibers, and/or para-aramid fibers (e.g., KEVLAR ™).

In some examples, base <NUM> is constructed of multiple layers, or plies, of the continuous fiber reinforced thermoplastic composite. In some such examples, the plies are pre-preg plies, which are layers of the composite that include the thermoplastic matrix material and a layer of continuous fibers. Accordingly, in some examples, multiple pre-preg plies are layered to collectively define a blank, or sheet, of the continuous fiber reinforced composite material having desired properties and characteristics. To more permanently affix adjacent layers of plies together, the layered plies may be compacted, or compressed, together with heat, utilizing any suitable method and at any suitable and various times during the construction of the continuous fiber reinforced thermoplastic composite. This compression of two more layers is referred to as compaction, or as compacting, of the plies, or layers, of fibers that are pre-impregnated with the thermoplastic matrix material. Additionally or alternatively, in some examples, the continuous fibers are comingled with filaments or fibers of the thermoplastic matrix material and formed or woven into a mat that is consolidated with heat and pressure. As another example, the continuous fibers are powder coated with a powder of the thermoplastic matrix material and formed or woven into a fabric that is consolidated with heat and pressure.

As mentioned, window frame <NUM> comprises at least one, and optionally a plurality of, overmolded features <NUM> molded to base <NUM> In some examples, overmolded feature <NUM> is configured to replace and/or supplement one or more external structures utilized in conventional aircraft window assemblies that is operatively attached to a window frame thereof. Additionally or alternatively, in some examples, overmolded feature <NUM> is configured to permit base <NUM> to be shaped with geometries that are not possible in conventional composite aircraft window assemblies. As discussed in more detail herein, more specific examples of overmolded features <NUM> that may be comprised in window frame <NUM> include an overmolded protruding rib <NUM>, an overmolded aero filler <NUM>, an inside edge overmold <NUM>, an outside edge overmold <NUM>, and/or a plurality of overmolded protrusions <NUM>. Window frame <NUM> may comprise at least one of, any suitable combination of two or more of, and/or each of overmolded protruding rib <NUM>, overmolded aero filler <NUM>, inside edge overmold <NUM>, outside edge overmold <NUM>, and/or overmolded protrusions <NUM>.

Each overmolded feature <NUM> is formed of an overmolding material that may comprise an overmolding matrix material, and optionally reinforcing elements embedded in the overmolding matrix material. In some examples, the overmolding matrix material is formed of at least one, and optionally a mixture of more than one, thermoplastic polymer. More specific examples of suitable thermoplastic polymers for forming the overmolding matrix material comprise low-melt polyaryletherketone (PAEK) polymers, polyphenylene sulfide (PPS), polyether ether ketone (PEEK), and polyetherketoneketone (PEEK).

The overmolding matrix material may be the same as or different from the thermoplastic matrix material of base <NUM>. Generally speaking, the overmolding matrix material is selected to be compatible with the thermoplastic matrix material of base <NUM> such that polymer chains of the overmolding matrix material may intermingle with those of the thermoplastic matrix material to form a bond or connection between overmolded feature <NUM> and base <NUM>. In some examples, the overmolding material is configured to possess similar, or at least substantially similar, mechanical properties to that of the continuous fiber reinforced thermoplastic composite of base <NUM> such that overmolded feature(s) <NUM> and base <NUM> react to applied loads in a similar manner and/or such as to avoid stress concentration in window frame <NUM>.

As discussed in more detail herein with reference to <FIG> and methods <NUM>, in some examples, overmolded feature <NUM> is molded to base <NUM> by melting the overmolding material and fusing, or welding, the overmolded matrix material with a desired region of the base <NUM>. Typically, the desired region of base <NUM> is melted during the welding process. In some examples, molding of the overmolded feature <NUM> to the base <NUM> comprises interdiffusing the overmolding matrix material with the thermoplastic matrix material of base <NUM> to form a bond or polymer weld therebetween. In some examples, the polymer chains of the overmolding matrix material and those of the thermoplastic matrix material intermingle or interdiffuse such as to form a continuous joint therebetween. Thus, in some examples, overmolded feature <NUM> is integrally molded with and/or continuous with base <NUM>.

As also discussed in more detail herein, in some examples, overmolded feature <NUM> is molded to base <NUM> by extruding the overmolding material onto a desired region of the base <NUM>. With this in mind, for some examples in which the overmolding material comprises reinforcing elements, the reinforcing elements do not comprise continuous fibers. In more specific examples, the reinforcing elements comprise short fibers, chopped fibers, or reinforcing particles. The reinforcing elements are formed of any suitable material, such as the same or different from the materials that form the continuous fibers of the base <NUM>. In some examples, the reinforcing elements are formed of glass or carbon, such as chopped or short glass fibers and/or chopped or short carbon fibers. The length and/or size of the reinforcing elements may be similar to that typically utilized in the art for injection molding. For examples in which window frame <NUM> comprises a plurality of overmolded features <NUM>, overmolded features <NUM> may be formed from the same overmolding material or from different overmolding materials that may be selected based upon the specific type of overmolded feature <NUM>.

With continued reference to <FIG> and <FIG>, in some examples, aircraft window assembly <NUM> comprises a pane retention system <NUM> that is configured to press window pane <NUM> against support surface <NUM> to retain window pane <NUM> on window frame <NUM>. In some examples, overmolded feature(s) <NUM> is, or comprises, an overmolded protruding rib <NUM> that is overmolded along interior face <NUM> of base <NUM>. Overmolded protruding rib <NUM> additionally or alternatively may be referred to herein as an overmolded vertical flange <NUM> and/or overmolded upright flange <NUM>. In some examples, aircraft window assembly <NUM> comprises a plurality of fastener receivers <NUM> disposed along overmolded protruding rib <NUM> and configured to couple pane retention system <NUM> to window frame <NUM>. In particular, in some examples, pane retention system <NUM> comprises a plurality of fasteners <NUM>, each being configured to engage a fastener receiver <NUM>. In some examples, fastener receivers <NUM> comprise threaded inserts that are installed through the interior face <NUM> of overmolded protruding rib <NUM>. In such example, fasteners <NUM> comprise threaded fasteners configured to be treaded into the threaded inserts.

In some examples, pane retention system <NUM> comprises a plurality of pane retention members <NUM>, each being configured to press window pane <NUM> against support surface <NUM> of skirt portion <NUM>. In some such examples, fasteners <NUM> are configured to couple a pane retention member <NUM> to a respective fastener receiver <NUM> disposed along overmolded protruding rib <NUM>. In some examples, each pane retention member <NUM> comprises a pane-contacting end region <NUM> configured to engage window pane <NUM> and a fastener-receiving region <NUM> configured to couple pane retention member <NUM> to overmolded protruding rib <NUM> via a respective fastener <NUM> and fastener receiver <NUM>.

Pane retention system <NUM> comprises any suitable number of pane retention members <NUM>, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM> pane retention members <NUM>. In some examples, aircraft window assembly <NUM> has a corresponding number of fastener receivers <NUM> disposed along overmolded protruding rib <NUM>. In some examples, fastener receivers <NUM> are spaced apart from one another along the circumference of overmolded protruding rib <NUM>. In this way, pane retention members <NUM> are positioned to contact circumferentially spaced apart portions of window pane <NUM> when coupled to fastener receivers <NUM>.

As shown in the examples of <FIG>, in some examples, overmolded protruding rib <NUM> protrudes from base <NUM> transverse to, and/or at least substantially normal to, circumferential flange portion <NUM>. In such examples, overmolded protruding rib <NUM> is configured to support fastener-receiving region <NUM> of pane retention member <NUM> spaced apart from base <NUM> such that pane retention member <NUM> is cantilevered from overmolded protruding rib <NUM>. In some examples, pane retention member <NUM> comprises an inverted L-shape or elbow-shape configuration, in which a first portion of pane retention member <NUM> extends from fastener-receiving region <NUM> radially inward towards central axis <NUM> and a second portion of pane retention member <NUM> extends towards support surface <NUM> and terminates as pane-contacting end region <NUM>. Pane retention member <NUM> additionally or alternatively may be referred to herein as pane retention clip <NUM>.

In some examples, overmolded protruding rib <NUM> is configured to stiffen base <NUM> against in-plane and out-of-plane deflections. In particular, overmolded protruding rib <NUM> may add structural dimension to window frame <NUM> transverse to circumferential flange portion <NUM> that strengthens window frame <NUM> against deflection or bending in directions transverse to circumferential flange portion <NUM>.

Overmolded protruding rib <NUM> may be molded to any suitable region of base <NUM> and/or extend along any suitable region of base <NUM>. In some examples, overmolded protruding rib <NUM> forms a closed ring centered about central axis <NUM>. More specifically, in some examples, overmolded protruding rib <NUM> extends at a fixed radial distance (i.e., measured along circumferential radius <NUM>) between an inside edge <NUM> and an outside edge <NUM> of base <NUM> to form a ring that extends along interior face <NUM>. In some examples, the ring formed by overmolded protruding rib <NUM> encircles central aperture <NUM> and at least a region of skirt portion <NUM>, in which the region of skirt portion <NUM> extends radially inward from overmolded protruding rib <NUM> towards central aperture <NUM>. In such examples, the region of skirt portion comprises support surface <NUM>. Stated in slightly different terms, overmolded protruding rib <NUM> may be molded to base <NUM> along circumferential flange portion <NUM> and optionally along a radially exterior region of skirt portion <NUM>. As shown in <FIG>, in some examples, overmolded protruding rib <NUM> is molded to base <NUM> to overlap with an intersection <NUM> of skirt portion <NUM> and circumferential flange portion <NUM> such that overmolded protruding rib <NUM> is molded to both circumferential flange portion <NUM> and skirt portion <NUM>. In some examples, overmolded protruding rib <NUM> is shaped to the global curvature of circumferential flange portion <NUM> and/or window frame <NUM>.

As shown in <FIG>, in some examples, overmolded protruding rib <NUM> comprises a plurality of radially-bulged sections <NUM>. When comprised in overmolded protruding rib <NUM>, radially-bulged sections <NUM> each comprise an outermost radial dimension that is greaterthan that of the remainder of overmolded protruding rib <NUM>. More specifically, in some examples, overmolded protruding rib <NUM> comprises an inside face that faces central axis <NUM> and an outside face that is opposed to inside face and that faces away from central axis <NUM>. In such examples, the outermost radial dimension of overmolded protruding rib is measured along circumferential radius <NUM> between the inside face and the outside face of overmolded protruding rib <NUM>. In some examples, radially-bulged sections <NUM> protrude away from central axis <NUM>, such that the inside face of overmolded protruding rib <NUM> is smooth while the outside face of overmolded protruding rib <NUM> extends further from central axis <NUM> along radially-bulged sections <NUM>.

In some examples, fastener receivers <NUM> are disposed along radially-bulged sections <NUM>. In some examples, radially-bulged sections <NUM> are widened relative to the remainder of overmolded protruding rib <NUM> such as to be dimensioned to accommodate fastener receivers <NUM> and/or such as to strengthen overmolded protruding rib <NUM> proximate to fastener receivers <NUM>. As shown in <FIG>, radially-bulged sections <NUM> may be spaced apart from one another about the circumference of overmolded protruding rib <NUM>. In some examples, the number of radially-bulged sections comprised in overmolded protruding rib <NUM> corresponds to the number of pane retention members <NUM> comprised in pane retention system <NUM>.

With continued reference to <FIG> and <FIG>, skirt portion <NUM> extends into window aperture <NUM> when window frame <NUM> is attached to aircraft skin <NUM> about window aperture <NUM>. In some examples, base <NUM> of window frame <NUM> is configured such that a gap <NUM> separates skirt portion <NUM> from aircraft skin <NUM>. In some examples, overmolded feature(s) <NUM> of window frame <NUM> is, or comprises, an overmolded aero filler <NUM> that is molded along exterior face <NUM> of skirt portion <NUM> and configured to be positioned within gap <NUM>. In some examples, overmolded aero filler <NUM> is dimensioned and shaped to at least partially fill gap <NUM> and/or smooth a transition between aircraft window assembly <NUM> and skin exterior surface <NUM> of aircraft skin <NUM>. With this in mind, overmolded aero filler additionally or alternatively may be referred to herein as overmolded smoother <NUM> and/or overmolded aero smoother <NUM>.

As shown in <FIG>, gap <NUM> is comprised in, or positioned within, window aperture <NUM>. In particular, in some examples, aircraft skin <NUM> comprises an aperture-facing edge <NUM> that surrounds window aperture <NUM> and extends between skin interior surface <NUM> and skin exterior surface <NUM>. In some examples, gap <NUM> is at least partially defined between aperture-facing edge <NUM> of aircraft skin <NUM> and exterior face <NUM> of skirt portion <NUM>. Thus, in some examples, gap <NUM> is a ring-shaped void and extends between exterior face <NUM> of skirt portion <NUM> and aperture-facing edge <NUM> of aircraft skin <NUM> along the entire circumference of skirt portion <NUM> and/or for all angles about central axis <NUM>. With this in mind, in some examples, overmolded aero filler <NUM> extends along the entire circumference of skirt portion <NUM> such as to encircle central aperture <NUM>. Stated another way, in some examples, overmolded aero filler <NUM> forms a closed ring centered about central axis <NUM>.

In some examples, window frame <NUM> is dimensioned and shaped such that intersection <NUM> is positioned adjacent to and/or aligned with aperture-facing edge <NUM> when window frame <NUM> is operatively coupled to aircraft skin <NUM> about window aperture <NUM>. In some such examples, exterior face <NUM> of skirt portion <NUM> is non-contacting with aircraft skin <NUM> and extends into window aperture <NUM> from, or from adjacent to, aperture-facing edge <NUM>. In some examples, overmolded aero filler <NUM> extends along exterior face <NUM> of skirt portion <NUM> from inside edge <NUM> of base <NUM> towards intersection <NUM>. In some examples, overmolded aero filler <NUM> terminates adjacent to intersection <NUM> and/or inside of intersection <NUM> such that overmolded aero filler <NUM> is positioned closely adjacent to, and optionally non-contacting with, aperture-facing edge <NUM> of aircraft skin <NUM>.

As perhaps best seen in the examples of <FIG>, in some examples, skirt portion <NUM> extends at a ramp angle <NUM> relative to circumferential flange portion <NUM>. In some examples, at least a substantial portion of, and optionally an entirety of, skirt portion <NUM> extends at ramp angle <NUM> relative to circumferential flange portion <NUM>. In other words, in a cross-section of base <NUM> taken along a plane that comprises central axis <NUM> and circumferential radius <NUM>, skirt portion <NUM> may be deflected from, or diverge from, circumferential flange portion <NUM> at a single bend that is centered at the intersection <NUM> of circumferential flange portion <NUM> and skirt portion <NUM>. Stated yet another way, in a cross-section of base <NUM> taken along a plane that comprises central axis <NUM> and circumferential radius <NUM>, circumferential flange portion <NUM> and skirt portion <NUM> each may extend along at least substantially straight lines towards intersection <NUM>. In some examples, ramp angle <NUM> is measured at intersection <NUM> between the lines along which circumferential flange portion <NUM> and skirt portion <NUM> respectively extend. In some such examples, support surface <NUM> also extends at ramp angle <NUM> relative to circumferential flange portion <NUM>.

As defined herein, ramp angle <NUM> is zero for a hypothetical configuration in which skirt portion <NUM> and circumferential flange portion are collinear in the above-mentioned cross-section and increases to <NUM> ° for a hypothetical configuration in which skirt portion <NUM> extends normal to circumferential flange portion. Base <NUM> may be shaped with any suitable ramp angle <NUM>, with more specific examples of suitable ramp angles <NUM> including at least <NUM>°, at least <NUM>°, at least <NUM>°, at least <NUM>°, at least <NUM>°, at least <NUM>°, at least <NUM>°, at least <NUM>°, at least <NUM>°, at least <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, at most <NUM>°, and/or at most <NUM>°.

In some examples, the volume of gap <NUM> decreases with respect to ramp angle <NUM>. As indicated above, in some examples, overmolded aero filler <NUM> is dimensioned and shaped to at least substantially fill the volume of gap <NUM>. In some such examples, the volume of overmolded aero filler <NUM> is selected based upon ramp angle <NUM>, and more particularly, increased for bases formed with smaller ramp angles <NUM>.

In some examples, base <NUM> is dimensioned and shaped such that skirt portion <NUM> extends at least substantially through, or entirely through, window aperture <NUM> such that inside edge <NUM> of base <NUM> is aligned with, or at least substantially aligned with, skin exterior surface <NUM>. In some examples, overmolded aero filler <NUM> comprises a wedge-shaped cross sectional shape in a plane that comprises central axis <NUM> and circumferential radius <NUM>. In particular, in some examples, overmolded aero filler <NUM> comprises an exterior surface <NUM> that is positioned to face the region <NUM> exterior to aircraft <NUM> when aircraft window assembly <NUM> is installed in aircraft, and overmolded aero filler <NUM> is dimensioned and shaped such that exterior surface <NUM> is aligned with, is at least substantially aligned with, and/or extends at least substantially parallel to skin exterior surface <NUM>. In some examples, overmolded aero filler <NUM> is shaped such that exterior surface <NUM> thereof extends at a deflection angle <NUM> relative to exterior face <NUM> of skirt portion <NUM>. In some such examples, the magnitude of deflection angle <NUM> is selected to be at least substantially the same as a magnitude of ramp angle <NUM> such that exterior surface <NUM> extends at least substantially parallel to skin exterior surface <NUM>. In other words, in some examples, deflection angle <NUM> and ramp angle <NUM> define opposite angles.

Overmolded aero filler <NUM> may permit base <NUM> to be shaped with a smaller degree of curvature between circumferential flange portion <NUM> and skirt portion <NUM>. In particular, by at least partially filling the gap <NUM> between exterior face <NUM> of skirt portion <NUM> and aircraft skin <NUM>, overmolded aero filler <NUM> may permit skirt portion <NUM> to be deflected, or diverge, from circumferential flange portion <NUM> at a single bend, whereas the base of conventional aircraft window frames that are formed from of continuous fiber reinforced composite materials typically are formed with two bends between the portion that contacts the aircraft skin and the portion that supports the window pane. By filling the gap between exterior face <NUM> of skirt portion <NUM> and aircraft skin <NUM>, overmolded aero filler <NUM> also may permit base <NUM> to be formed with a smaller radius of curvature in the bend between skirt portion <NUM> than the bends of conventional aircraft window frames formed from of continuous fiber reinforced composite materials. The smaller number of bends in base <NUM> and/or the smaller radius of curvature thereof as permitted by overmolded aero filler <NUM> may reduce wrinkling of the continuous fibers within base <NUM>, which may improve the strength and/or structural integrity thereof.

In some examples, overmolded aero filler <NUM> is configured to stiffen skirt portion <NUM> and/or strengthen skirt portion <NUM> against in-plane and out-of-plane deflections, such as for similar reasons to that discussed herein for overmolded protruding rib <NUM>. In some examples, overmolded aero filler <NUM> also is configured to strengthen skirt portion <NUM> for supporting window pane <NUM>. In particular, in some examples, at least a portion of overmolded aero filler <NUM> is molded to skirt portion <NUM> immediately opposed to support surface <NUM> such that overmolded aero filler <NUM> may provide additional structural backing along the region of skirt portion that directly supports window pane <NUM>. As perhaps best seen in the examples of <FIG>, pane exterior surface <NUM> is supported on support surface <NUM> of skirt portion <NUM>. In some examples, the peripheral region of pane exterior surface <NUM> that is supported on support surface <NUM> is beveled or angled. In some such examples, the peripheral region of pane exterior surface <NUM> is beveled or angled corresponding to ramp angle <NUM>.

With continued reference to <FIG> and <FIG>, in some examples, base <NUM> comprises an inside edge <NUM> that extends between interior face <NUM> and exterior face <NUM> and that directly interfaces central aperture. In some examples, base <NUM> additionally or alternatively comprises an outside edge <NUM> that extends between interior face <NUM> and exterior face <NUM> and that extends around circumferential flange portion <NUM>. In some examples, overmolded feature(s) <NUM> is, or comprise, an inside edge overmold <NUM> that is molded along inside edge <NUM>, and optionally along the entirety of inside edge <NUM>. Additionally or alternatively, in some examples, overmolded feature(s) <NUM> is, or comprise, an outside edge overmold <NUM> that is molded along outside edge <NUM>, and optionally along the entirety of outside edge <NUM>. In such examples, outside edge overmold <NUM> defines the radial exterior of window frame <NUM>.

In some examples, inside edge overmold <NUM> and/or outside edge overmold <NUM> are configured to seal, protect, and/or shield the respective edge of base <NUM>. As an example, for some examples in which the continuous fiber reinforced thermoplastic composite of base <NUM> comprises continuous carbon fibers, inside edge overmold <NUM> and/or outside edge overmold <NUM> are configured to protect base <NUM> against electromagnetic effects. Additionally or alternatively, in some examples, inside edge overmold <NUM> and/or outside edge overmold <NUM> are configured to provide corrosion protection such as for, or to, any metallic structure proximate or in contact with window frame <NUM> when aircraft window assembly <NUM> is installed in aircraft <NUM>. In view of the above, for some examples in which the overmolding material of inside edge overmold <NUM> and/or outside edge overmold <NUM> comprises reinforcing particles, the reinforcing particles are selected to be non-conducting such as chopped or short glass fibers.

As perhaps best seen in <FIG>, in some examples, window frame <NUM> comprises a plurality of window frame fastener bores <NUM> extending through and spaced apart around circumferential flange portion <NUM>. Window frame fastener bores <NUM> are configured to receive a respective plurality of window frame fasteners <NUM> that engage with aircraft skin <NUM> to retain window frame <NUM> to aircraft skin <NUM>. In some examples, overmolded feature(s) <NUM> is, or comprises, a plurality of overmolded protrusions <NUM>, each being molded atop a window frame fastener bore <NUM>. In particular, when window frame <NUM> comprises overmolded protrusions <NUM>, overmolded protrusions <NUM> are molded on interior face <NUM> of circumferential flange portion <NUM>. Each overmolded protrusion <NUM> is configured to receive and secure a window frame fastener receiver <NUM> to window frame <NUM>, and window frame fastener receivers <NUM> are configured to receive and engage a window frame fasteners <NUM> to retain window frame <NUM> to aircraft skin <NUM>. In some examples, window frame fastener receivers <NUM> comprise threaded inserts that are installed into overmolded protrusions <NUM>. In particular, in some examples, the threaded inserts are disposed in, or co-molded with, the overmolded protrusions during overmolding of the overmolded protrusions <NUM> to the base <NUM>. Alternatively, the threaded inserts may be tapped or otherwise installed in the overmolded protrusions <NUM> after they are overmolded to the base <NUM>. Window frame <NUM> may comprise any suitable number of overmolded protrusions <NUM>, such as at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at least <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, at most <NUM>, and/or at most <NUM> overmolded protrusions <NUM>.

<FIG> and <FIG> provide an illustrative, non-exclusive example of window frame <NUM> that is indicated at and referred to herein as window frame <NUM>. Where appropriate, the reference numerals from schematic <FIG> are used to designate corresponding parts of the example window frame <NUM> of <FIG>; however, window frame <NUM> is non-exclusive and does not limit aircraft window assemblies <NUM> and/or window frames <NUM> thereof to the illustrated embodiments of <FIG>. That is, aircraft window assemblies <NUM> and/or window frames <NUM> thereof may incorporate any of the various aspects, configurations, characteristics, properties, variants, options etc. of aircraft window assemblies <NUM> and/or window frames <NUM> thereof <NUM> that are illustrated in and discussed with reference to the schematic representation of <FIG> and/or the embodiment of <FIG>, as well as variations thereof, without requiring the inclusion of all such aspects, configurations, characteristics, properties, variants, options etc. Furthermore, any additional aspects, configurations, characteristics, properties, variants, options, etc. disclosed in connection with the example window frame <NUM> of <FIG> may be utilized with and/or otherwise comprised in aircraft window assemblies <NUM> and/or window frame <NUM> thereof, including those according to <FIG>. For the purpose of brevity, each previously discussed component, part, portion, aspect, region, etc. or variants thereof may not be discussed, illustrated, and/or labeled again with respect to the example of <FIG>; however, it is within the scope of the present disclosure that the previously discussed features, variants, etc. may be utilized with the example of <FIG>.

More specifically, <FIG> is an isometric view of window frame <NUM>, and <FIG> is a cross-sectional view taken along line <NUM>-<NUM> of <FIG>. With reference to <FIG> and <FIG>, window frame <NUM> comprises base <NUM> having circumferential flange portion <NUM> and skirt portion <NUM> extending radially inward from circumferential flange portion <NUM> to encircle central aperture <NUM>. Skirt portion <NUM> deflects, or diverges, from circumferential flange portion at a single bend that is centered at the intersection <NUM> of skirt portion <NUM> and circumferential flange portion <NUM>. Stated differently, at least a substantial portion of, or the entirety of skirt portion <NUM> extends at the ramp angle relative to the circumferential flange portion <NUM> along line <NUM>-<NUM>.

Window frame <NUM> also comprises overmolded protruding rib <NUM> that extends as a ring along interior face <NUM> of base <NUM>. Overmolded protruding rib <NUM> protrudes outwardly from base <NUM> in a direction that is transverse to, and optionally normal to, circumferential flange portion <NUM>. In this example, overmolded protruding rib <NUM> is molded to base <NUM> along, or radially aligned with, intersection <NUM>. Overmolded protruding rib <NUM> comprises a plurality of radially-bulged sections <NUM> that are spaced apart from one another along the circumference of overmolded protruding rib <NUM>. Each radially-bulged section <NUM> protrudes radially outward from an outside face <NUM> of overmolded protruding rib <NUM>, such that an inside face <NUM> of overmolded protruding is smooth and/or not bulged. A plurality of fastener receivers <NUM> are disposed along overmolded protruding rib <NUM>, with each extending into and/or being surrounded by a respective radially-bulged section <NUM>. Each fastener receivers <NUM> may comprise a threaded bore and/or threaded insert that is set into radially-bulged section <NUM>.

Window frame <NUM> also comprises overmolded aero filler <NUM> that is molded along exterior face <NUM> of skirt portion <NUM>. Overmolded aero filler <NUM> is wedge-shaped in the cross-section <NUM>-<NUM> shown in <FIG> such that the exterior surface <NUM> extends at least substantially parallel to circumferential flange portion <NUM>. Overmolded aero filler <NUM> extends from proximate to inside edge <NUM> of base <NUM>, along exterior face <NUM> of base <NUM> towards intersection <NUM>, and terminates radially inside of intersection <NUM>.

<FIG> provides a flowchart that represents illustrative, non-exclusive examples of methods <NUM> of forming a window frame according to the present disclosure. In <FIG>, some steps are illustrated in dashed boxes indicating that such steps may be optional, or may correspond to an optional version of methods <NUM> according to the present disclosure. That said, not all methods <NUM> according to the present disclosure are required to comprise each of the steps illustrated in solid boxes. The methods and steps illustrated in <FIG> are not limiting, and other methods and steps are within the scope of the present disclosure, including methods having greater than or fewer than the number of steps illustrated, as understood from the discussion herein.

Methods <NUM> may be performed to form window frame <NUM>, of aircraft window assemblies <NUM>, that is illustrated and discussed herein with reference to <FIG>. That is, the window frame formed according to methods <NUM> and/or discussed herein with reference to <FIG> and methods <NUM> may incorporate any of the features, functions, components, materials etc., as well as variants thereof, as those discussed herein with reference to <FIG> without requiring the inclusion of all such features, functions, components, materials etc. Likewise, window frame <NUM> discussed herein with reference to <FIG> may incorporate any of the features, functions, components, materials etc. as those discussed herein with reference to <FIG> and methods <NUM>, without requiring the inclusion of all such features, functions, components, materials etc. Where appropriate, the reference numerals from <FIG> may be utilized to indicate corresponding parts of the window frames discussed herein with reference to <FIG> and methods <NUM>.

Methods <NUM> comprise stamp-forming a base of the window frame at <NUM>, and overmolding at least one overmolded feature on the base at <NUM>. The stamp-forming at <NUM> may comprise deflecting a skirt portion of the base from a circumferential flange portion of the base at <NUM>. The overmolding at <NUM> may comprise positioning an overmolding die at <NUM>, extruding an overmolding material at <NUM>, and welding the overmolding material with the base at <NUM>.

The stamp-forming at <NUM> comprises stamp-forming the base <NUM> of the window frame <NUM> from a sheet of continuous fiber reinforced thermoplastic composite. The sheet of continuous fiber reinforced thermoplastic composite may be formed from any of the material compositions discussed herein with reference to base <NUM> and <FIG> and <FIG>. As examples, the sheet of continuous fiber reinforced thermoplastic composite may be formed of multiple layers or plies that are compressed together with heat to form the sheet of continuous fiber reinforced thermoplastic composite. In some examples, each ply or layer within the sheet comprises a corresponding layer of continuous fibers embedded therein. The continuous fibers of a given layer may be aligned with one another and/or woven. The continuous fibers of a given layer also may extend at a different orientation relative to the continuous fibers of layers adjacent to the given layer.

In some examples, the stamp-forming at <NUM> comprises heating the sheet of continuous fiber reinforced thermoplastic composite to soften the continuous fiber reinforced thermoplastic composite, and/or heating the sheet of continuous fiber reinforced thermoplastic composite to or above a softening temperature of the thermoplastic matrix material of the of continuous fiber reinforced thermoplastic composite. As referred to herein, the softening temperature may be defined as a transition temperature of the thermoplastic matrix material at or above which the thermoplastic matrix material is adequately softened and/or malleable to permit mobility of the polymer chains thereof. In some examples, a temperature at or above the softening temperature is suitable to perform welding at <NUM> of the thermoplastic matrix material of the base <NUM> with the overmolding matrix material of the at least one overmolding material. The softening temperature is governed by the specific type of thermoplastic matrix material comprised in the base <NUM>. More specific examples of the softening temperature comprise a glass transition temperature of the thermoplastic matrix material, a temperature above the glass transition temperature of the thermoplastic matrix material, a temperature between the glass transition temperature and the melting point of the thermoplastic matrix material, the melting point of the thermoplastic matrix material, and/or a temperature above the melting point of the thermoplastic matrix material.

Thus, in some examples, the stamp-forming at <NUM> comprises heating the sheet of continuous fiber reinforced thermoplastic composite to, or above, the softening temperature of the thermoplastic matrix material of the of continuous fiber reinforced thermoplastic composite. At least substantially simultaneously with, or subsequent to, the heating, the stamp-forming at <NUM> may comprise shaping the sheet of continuous fiber reinforced thermoplastic composite into the shape of the base <NUM>. In some examples, the shaping comprises cutting, or stamping, the outside edge <NUM> of the base <NUM> from the sheet of continuous fiber reinforced thermoplastic composite. In some examples, the shaping also comprises forming the central aperture <NUM> within the base <NUM>, such as by cutting, or stamping the inside edge <NUM> of the base. The shaping also may comprise shaping the base <NUM> into the global curvature discussed herein.

In more specific examples, the shaping comprises utilizing a stamp press. In some such examples, the stamp press comprises a mold and a stamp die that are brought together to form a space therebetween that defines the desired shape of base <NUM>. In some such examples, the stamp-forming comprises positioning the sheet of continuous fiber reinforced thermoplastic composite between the mold and the stamp die, moving the stamp die towards the mold to press the sheet of continuous fiber reinforced thermoplastic composite into the mold, and compressing the continuous fiber reinforced thermoplastic composite in the mold with the stamp die to form the continuous fiber reinforced thermoplastic composite into the desired shape of the base <NUM>. In some such examples, the mold contacts or supports the exterior face <NUM> of the base <NUM> during the shaping and the stamp die contacts or supports the interior face <NUM> of the base <NUM> during the shaping.

As shown in <FIG>, in some examples, the stamp-forming at <NUM> comprises deflecting a skirt portion of the base <NUM> from the circumferential flange portion of the base at <NUM>. The deflecting at <NUM> additionally or alternatively may be described as forming the skirt portion <NUM> and the circumferential flange portion <NUM> in the base <NUM>. In some examples, the deflecting at <NUM> is performed as a portion of the shaping and/or at least substantially simultaneously with or subsequent to the heating. In some examples, the deflecting at <NUM> comprises forming a bend between the skirt portion and the circumferential flange portion. In some examples, the deflecting at <NUM> also comprises deflecting the skirt portion <NUM> from the circumferential flange portion <NUM> such that the skirt portion <NUM> extends at the ramp angle relative to the circumferential flange portion. Examples of the suitable ramp angles are disclosed herein.

Methods <NUM> further comprise overmolding the at least one overmolded feature on the base at <NUM>. The overmolding at <NUM> may comprise overmolding any of the overmolded features <NUM> to the base that are discussed herein. As examples, the overmolding at <NUM> may comprise overmolding the overmolded protruding rib <NUM>, the overmolded aero filler <NUM>, the inside edge overmold <NUM>, and/or the outside edge overmold <NUM> to the base <NUM>. In some examples, the overmolding at <NUM> comprises overmolding a plurality of overmolded features <NUM> to the base. In some examples, the overmolding at <NUM> comprises overmolding the plurality of overmolded features <NUM> to the base at least substantially simultaneously with one another. Alternatively, in some examples, the overmolding at <NUM> comprises overmolding two or more of the overmolded features <NUM> to the base in a sequential manner.

In some examples, the overmolding at <NUM> comprises molding the at least one overmolded feature <NUM> along a respective desired region of the base <NUM>. In such examples, the desired region of the base <NUM> is selected based upon the particular overmolded feature <NUM>. For some examples in which the at least one overmolded feature <NUM> comprises the overmolded aero filler <NUM>, the desired region of the base <NUM> for overmolding the overmolded aero smoother <NUM> extends circumferentially about the interior face <NUM> of the skirt portion <NUM> from the inside edge <NUM> of the base <NUM> to a fixed distance from the inside edge <NUM>. For examples in which the at least one overmolded feature <NUM> comprises the overmolded protruding rib <NUM>, the desired region of the base <NUM> comprises a ring that extends along the exterior face of the base <NUM>. For some examples in which the at least one overmolded feature <NUM> comprises the inside edge overmold <NUM>, the desired region of the base <NUM> comprises the inside edge <NUM> of the base <NUM>. For some examples in which the at least one overmolded feature comprises the outside edge overmold <NUM>, the desired region of the base comprises the outside edge <NUM> of the base <NUM>.

As shown in <FIG>, in some examples, the overmolding comprises positioning an overmolding die in contact with the base at <NUM>. In some examples, the overmolding die comprises an embossed template for the at least one overmolded feature <NUM>. In some examples, the embossed template comprises a void in the shape of the respective overmolded feature with an open face corresponding to the region along which the overmolded feature <NUM> is molded to the base. In some such examples, the positioning at <NUM> comprises positioning the overmolded die such that the embossed template for the at least one overmolded feature interfaces and/or is aligned with the desired region of the base <NUM>. In some examples, the overmolding die comprises an embossed template for a plurality of the overmolded features <NUM>, and the positioning at <NUM> comprises positioning the overmolding die such that the embossed template for each of the plurality of overmolded features interfaces and/or is aligned with the respective desired region of the base <NUM>. Additionally or alternatively, in some examples, the overmolding at <NUM> comprises utilizing at least two overmolding dies, at least one of which being utilized to form at least one overmolded features <NUM> formed on the interior face <NUM> of the base <NUM> and the other of which being utilized to form an overmolded feature on the exterior face of the base <NUM>.

In some examples, the overmolding die is comprised in the stamp press that is utilized during the stamp-forming at <NUM>. In some such examples, the embossed template for the at least one overmolded feature is formed in the stamp die or the mold. As discussed in more detail herein, in some examples, the overmolding is performed at least substantially simultaneously with the stamp-forming at <NUM>. In a more specific example, the overmolding at <NUM> comprises utilizing a first overmolding die that is comprised in the mold to overmold the overmolded aero filler <NUM> to the exterior face <NUM> of the base <NUM>, and utilizing a second overmolding die that is comprised in the stamp die to overmold the overmolded protruding rib <NUM> to the interior face <NUM> of the base <NUM>.

In some examples, the overmolding at <NUM> further comprises extruding an overmolding material at <NUM>. When the overmolding comprises the extruding at <NUM>, the extruding at <NUM> comprises extruding the overmolding material from which the at least one overmolded feature <NUM> is formed into the embossed template such that the overmolding material fills the embossed template and contacts the desired region of the base <NUM>. As such, when comprised in the overmolding at <NUM>, the extruding at <NUM> is performed subsequent to the positioning at <NUM>. For some examples in which the overmolding at <NUM> comprises overmolding a plurality of overmolded features <NUM>, the extruding at <NUM> comprises extruding the overmolding material into each embossed template corresponding to each overmolded feature <NUM>. Also for some examples in which the overmolding at <NUM> comprises overmolding a plurality of overmolded features <NUM>, the extruding may comprise extruding each overmolded feature <NUM> at the same or different times from one another.

Generally speaking, the extruding at <NUM> comprises flowing the overmolded material into the embossed template. As such, the extruding at <NUM> further comprises melting the overmolded material, heating the overmolded material to or above its melting point, and/or maintaining the overmolding material at or above its melting point during the extruding at <NUM>.

In some examples, the overmolding at <NUM> comprises welding the at least one overmolded feature with the base along the desired region of the base at <NUM>. When comprised in the overmolding at <NUM>, the welding at <NUM> comprises welding the overmolding material from which the at least one overmolded feature <NUM> is formed with the continuous fiber reinforced thermoplastic composite of the base <NUM>. In some examples, the welding at <NUM> is performed at least substantially simultaneously with the extruding at <NUM>.

As discussed herein, in some examples, the overmolding material is formed of an overmolding matrix material, and optionally reinforcing elements embedded in the overmolding matrix material. In some examples, the welding at <NUM> comprises fusing and/or forming a thermoplastic bond between the overmolding matrix material and the matrix material of the base <NUM>. In particular, in some examples, the welding at <NUM> comprises intermingling and/or interdiffusing polymer chains of the overmolding matrix material with those of the matrix material of the base <NUM>. Thus, the welding at <NUM> additionally or alternatively is referred to as fusing, plastic welding, polymer welding, and/or thermoplastic welding.

Generally speaking, at least the portion of the overmolding material that contacts and/or is immediately proximate to the desired region of the base is liquid, melted, and/or at or above the melting point of the overmolding matrix material during the welding at <NUM>. Also generally speaking, at least the desired region of the base <NUM>, including a subsurface layer beneath the desired region, is melted and/or at or above the softening temperature of the thermoplastic matrix material of the base during the welding at <NUM>, such as to permit intermingling of the polymer chains of the thermoplastic matrix material and the overmolding matrix material.

In some examples, the overmolding at <NUM> and/or the welding at <NUM> are performed at least substantially simultaneously with the stamp-forming at <NUM>. In some such examples, the entirety of the base <NUM> is at or above the softening temperature thereof, such that the welding at <NUM> occurs automatically during and/or as a part of the extruding at <NUM>. In some such examples, the overmolding matrix material is selected to possess a melting point that is at least substantially the same as or the same as the melting point of the thermoplastic matrix material of the base <NUM>.

Additionally or alternatively, in some examples, the overmolding at <NUM> and/or the welding at <NUM> are performed subsequent to the stamp-forming at <NUM>. In some such examples, methods <NUM> comprise cooling the base <NUM> below the softening temperature thereof subsequent to the stamp-forming at <NUM> and prior to the overmolding at <NUM>. In such examples, methods <NUM> comprise heating at least the desired region of the base <NUM> prior to, and/or during the overmolding at <NUM> and/or the welding at <NUM>. In a more specific example, methods <NUM> comprise selectively heating the desired region of the base <NUM>, for example by utilizing a directed heating technique such as infrared heating and/or laser beam heating, prior to, or during the, overmolding at <NUM>. In some such examples, only the desired region of the base is above the softening temperature of the thermoplastic matrix material during the welding at <NUM>.

For some examples in which the overmolding at <NUM> and/or the welding at <NUM> are performed subsequent to the stamp-forming at <NUM>, the overmolding matrix material is selected to possess a melting point that is lower than the melting point and/or softening temperature of the thermoplastic matrix material of the base <NUM>. In such examples, the overmolding at <NUM> may be performed without softening any undesired region of the base and/or without altering the desired shape of the base <NUM>.

In some examples methods <NUM> comprise repeating at <NUM>. When comprised in methods <NUM>, the repeating at <NUM> comprises repeating any suitable number, subset, portion, of the steps of methods <NUM>, as well as substeps thereof, in any suitable order. Additionally, the repeating at <NUM> may comprise repeating any given step, or substep, in the same or in a different manner as originally performed.

In some examples, the repeating at <NUM> comprises repeating one or more steps of methods <NUM> an additional time, or a plurality of additional times, to form a single window frame <NUM>. As an example, for some examples in which methods <NUM> comprises forming a plurality of overmolded features, the repeating at <NUM> comprises repeating the overmolding at <NUM> at least once, and optionally a plurality of times, to form the plurality of overmolded features <NUM>. In some examples, the overmolding at <NUM> comprises overmolding a first subset of overmolded features <NUM>, and the repeating at <NUM> the overmolding at <NUM> comprises overmolding a second of overmolded features <NUM>. In some examples, the overmolding at <NUM> is performed at least substantially simultaneously with the stamp-forming at <NUM>, and the repeating at <NUM> the overmolding at <NUM> is performed subsequent to the stamp-forming <NUM>.

In some examples, the repeating at <NUM> comprises repeating a plurality of steps of methods <NUM> at least once, and optionally a plurality of times, such as to form a plurality of window frames <NUM>.

As used herein, the phrase, "for example," the phrase, "as an example," and/or simply the term "example," when used with reference to one or more components, features, details, structures, embodiments, and/or methods according to the present disclosure, are intended to convey that the described component, feature, detail, structure, embodiment, and/or method is an illustrative, non-exclusive example of components, features, details, structures, embodiments, and/or methods according to the present disclosure.

As used herein, the terms "selective" and "selectively," when modifying an action, movement, configuration, or other activity of one or more components or characteristics of an apparatus, mean that the specific action, movement, configuration, or other activity is a direct or indirect result of one or more dynamic processes, as described herein. The terms "selective" and "selectively" thus may characterize an activity that is a direct or indirect result of user manipulation of an aspect of, or one or more components of, the apparatus, or may characterize a process that occurs automatically, such as via the mechanisms disclosed herein.

As used herein, the term "and/or" placed between a first entity and a second entity means one of (<NUM>) the first entity, (<NUM>) the second entity, and (<NUM>) the first entity and the second entity. Multiple entries listed with "and/or" should be construed in the same manner, i.e., "one or more" of the entities so conjoined. Other entities optionally may be present other than the entities specifically identified by the "and/or" clause, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, a reference to "A and/or B," when used in conjunction with open-ended language such as "comprising," may refer, in one example, to A only (optionally including entities other than B); in another example, to B only (optionally including entities other than A); in yet another example, to both A and B (optionally including other entities). These entities may refer to elements, actions, structures, steps, operations, values, and the like.

As used herein, the phrase "at least one," in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more of the entities in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities. This definition also allows that entities may optionally be present other than the entities specifically identified within the list of entities to which the phrase "at least one" refers, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, "at least one of A and B" (or, equivalently, "at least one of A or B," or, equivalently "at least one of A and/or B") may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including entities other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including entities other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities). In other words, the phrases "at least one," "one or more," and "and/or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B, and C," "at least one of A, B, or C," "one or more of A, B, and C," "one or more of A, B, or C," and "A, B, and/or C" may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B, and C together, and optionally any of the above in combination with at least one other entity.

As used herein, "at least substantially," when modifying a degree or relationship, includes not only the recited "substantial" degree or relationship, but also the full extent of the recited degree or relationship. A substantial amount of a recited degree or relationship may include at least <NUM>% of the recited degree or relationship. For example, an object that is at least substantially formed from a material includes an object for which at least <NUM>% of the object is formed from the material and also includes an object that is completely formed from the material. As another example, a first direction that is at least substantially parallel to a second direction includes a first direction that forms an angle with respect to the second direction that is at most <NUM> degrees and also includes a first direction that is exactly parallel to the second direction. As another example, a first length that is substantially equal to a second length includes a first length that is at least <NUM>% of the second length, a first length that is equal to the second length, and a first length that exceeds the second length such that the second length is at least <NUM>% of the first length.

In the present disclosure, several of the illustrative, non-exclusive examples have been discussed and/or presented in the context of flow diagrams, or flow charts, in which the methods are shown and described as a series of blocks, or steps. Unless specifically set forth in the accompanying description, it is within the scope of the present disclosure that the order of the blocks may vary from the illustrated order in the flow diagram, including with two or more of the blocks (or steps) occurring in a different order, concurrently, and/or repeatedly. It is also within the scope of the present disclosure that the blocks, or steps, may be implemented as logic, which also may be described as implementing the blocks, or steps, as logics. In some applications, the blocks, or steps, may represent expressions and/or actions to be performed by functionally equivalent circuits or other logic devices. The illustrated blocks may, but are not required to, represent executable instructions that cause a computer, processor, and/or other logic device to respond, to perform an action, to change states, to generate an output or display, and/or to make decisions.

Claim 1:
An aircraft window assembly (<NUM>), comprising:
a window frame (<NUM>) configured to support a window pane (<NUM>) on an aircraft skin (<NUM>) around a circumference of a window aperture (<NUM>) defined in the aircraft skin (<NUM>) and to align the window pane (<NUM>) with the window aperture (<NUM>), wherein the window frame (<NUM>) comprises:
a base (<NUM>) formed of a continuous fiber reinforced thermoplastic composite, wherein the base (<NUM>) is ring-shaped and defines a central aperture (<NUM>), and wherein the base (<NUM>) comprises:
a circumferential flange portion (<NUM>) defining a radial exterior of the base (<NUM>) and configured to support the base (<NUM>) on the aircraft skin (<NUM>) surrounding the window aperture (<NUM>);
a skirt portion (<NUM>) extending radially inwardly from the circumferential flange portion (<NUM>) and surrounding the central aperture (<NUM>), wherein the skirt portion (<NUM>) is non-planar with the circumferential flange portion (<NUM>) and comprises a support surface (<NUM>) for supporting the window pane (<NUM>) of the aircraft window assembly (<NUM>);
characterized by:
at least one overmolded feature (<NUM>) molded to the base (<NUM>);
wherein the aircraft window assembly (<NUM>) further comprises a plurality of window frame fastener bores (<NUM>) extending through and spaced-apart around the circumferential flange portion (<NUM>) and configured to receive a respective plurality of window frame fasteners (<NUM>) to retain the window frame (<NUM>) to the aircraft skin (<NUM>), wherein the at least one overmolded feature (<NUM>) comprises a plurality of overmolded protrusions (<NUM>), wherein each overmolded protrusion (<NUM>) is molded atop a window frame fastener bore (<NUM>) of the plurality of window frame fastener bores (<NUM>), and wherein each overmolded protrusion is configured to receive a window frame fastener receiver (<NUM>), and wherein each window frame fastener receiver (<NUM>) is configured to receive and engage a window frame fastener (<NUM>) of the plurality of window frame fasteners (<NUM>).