Patent Description:
Aircraft generally include an airframe, which may be regarded as an underlying structure to which skin panels are attached to form a smooth aerodynamic outer surface. The wings of aircraft also include an underlying structure covered with skin panels. The underlying structure may include stringers, which together with longerons, formers, frames, ribs, spars, etc., form the structural framework. The skin panels are generally light and thin to minimize or reduce the weight of the aircraft and increase its payload and/or range. Since skin panels are thin, they are generally flexible and require stiffening in cooperation with the underlying structure to prevent undesired movement, flexing, and vibration of the skin panels during flight.

Often, stiffening of the skin panel is accomplished by joining stringers to the skin panels. However, joining stringers and skin panels requires multiple processing cycles, which is time-consuming and expensive. Therefore, a need exists for reducing cycle times and/or costs of joining stringers to skin panels, in instances where the stringers are used to reinforce the skin panels, while also keeping part counts and/or weight down or to a minimum.

<CIT>, in accordance with its abstract, states a composite structure is fabricated by staging at least a portion of an uncured, first composite component. The first composite component is assembled with a second composite component, and the staged portion of the first composite component is cocured with the second composite component.

In <CIT> there is described a method of bonding an upstanding rubber cleat or the like to a length of belt having a surface of cured rubber, said method comprising: abrading the cured rubber surface of said belt throughout a predetermined width in a surface area to which the cleat is to be applied, applying a vulcanizing cement to the abraded surface area of said belt, then pressing the base of a length of uncured rubber cleat stock of generally I-shaped cross section having a base width substantially less than the width of the abraded surface area of the belt against said abraded surface area and between the lateral limits of the abraded area, and while pressing said uncured cleat stock against said belt as aforesaid heating the uncured stock and thereby flowing the base of said cleat stock laterally onto the abraded surface area of said belt throughout substantially the entire width of said abraded area while restraining the remaining portions of said cleat stock against flowing deformation, and while pressing and heating said cleat stock as aforesaid controlling the flow of the base portion thereof so that said portion merges smoothly and gradually with the belt surface throughout the width of the abraded surface area thereof, and continuing the application of heat and pressure to said cleat stock to cure the same and provide a permanent bond with said belt surface.

<CIT>, in accordance with its abstract, states a method for improving the strength and quality of thermoplastic welds by annealing the weld following its formation at a temperature of at least about <NUM> DEG C. (<NUM> DEG F. ) (i.e., about <NUM> DEG C. (<NUM> DEG F. ) below the melt) for about <NUM> minutes to control cooling of the weld.

<CIT>, in accordance with its abstract, states a composite structure may include a laminate and a stabilizing element. The laminate may have a plurality of composite plies. The composite structure may include a geometric discontinuity that may be associated with the laminate. The stabilizing element may be included with the composite plies and may be located proximate the geometric discontinuity.

<CIT>, in accordance with its abstract, states a method for improving adhesion between polymeric materials is provided. The method includes treating a surface of a first polymeric material with plasma of oxygen gas and hydrogen-containing gas. The first polymeric material may be a fully cured polymeric material. A second polymeric material may then be deposited on the plasma treated surface of the first polymeric material. The second polymeric material may be an uncured polymeric material. This plasma treatment may be used in improving the adhesion between polymeric components of an inkjet printer. It provides adhesion between the polymeric components of the inkjet printer even after long exposure to ink.

<CIT> discloses a prepreg laminate having a woven fabric prepreg on at least one surface layer and having a discontinuous fiber prepreg, wherein the woven fabric prepreg includes reinforced fibers R1 with a woven structure and a thermosetting resin A, the discontinuous fiber prepreg includes discontinuous reinforced fibers R2 oriented in one direction and a thermosetting resin B, and the thermosetting resin A and thermosetting resin B satisfy a calorific value condition. Calorific value condition: When temperatures of the thermosetting resin A and thermosetting resin B are each raised by means of a differential scanning calorimetry analyzer to <NUM> in a nitrogen atmosphere at <NUM> to <NUM>/min and kept at <NUM> until the end of a thermosetting reaction, Tb-Ta><NUM>, where Ta(s) is the time until the calorific value of the thermosetting resin A reaches <NUM>% of the total calorific value of the thermosetting resin A and Tb(s) is the time until the calorific value of the thermosetting resin B reaches <NUM>% of the total calorific value of the thermosetting resin B. Based on the above, provided are the prepreg laminate exhibiting less irregularity in the texture of the woven structure during forming even when combining the woven fabric prepreg and discontinuous fiber prepreg, a fiber-reinforced plastic that has a pleasing appearance and is suitable as an external panel member, and a method for manufacturing the fiber-reinforced plastic.

One example of the present disclosure is directed to a method of forming a reinforced panel component for aircraft or any similar application. As used herein, a "reinforced panel component," "reinforced panel," and "reinforced component," all refer to the same element. In a particular example, a method of forming the reinforced panel component includes the application of heat and pressure to simultaneously, or substantially simultaneously (e.g., at the same time or at nominal difference in time), co-bond faying surfaces of a reinforcement component and a panel component together, and cure the panel component, so as to form the reinforced panel component. Simultaneously or substantially simultaneously co-bonding the faying surfaces and curing the panel component advantageously reduces the typical cycle times and costs of joining reinforcement components (e.g., composite stringers) to panel components (e.g., composite skin panels), while also keeping part counts and part weights to a minimum. For example, in one instance, a typical cycle time of about <NUM>-<NUM> hours using an autoclave is reduced to about <NUM>-<NUM> minutes using an example of the apparatus and method disclosed herein.

There is described herein a method of forming a reinforced panel, the method comprising: engaging a reinforcement component with a first portion of a heated press, the reinforcement component having a faying surface; engaging an uncured panel component with an opposing second portion of the press, the panel component having a faying surface complementarily-configured with respect to the faying surface of the reinforcement component; treating the faying surface of the reinforcement component such that the faying surface is active for co-bonding with respect to the panel component; actuating the press to direct the first and second portions of the press toward each other, such that the faying surfaces of the reinforcement component and the panel component are complementarily engaged under pressure; and heating the first and second portions of the press to a curing temperature associated with the panel component to simultaneously or substantially simultaneously co-bond the faying surfaces of the reinforcement component and the panel component together, cure the panel component, and form the reinforced panel; and wherein engaging the reinforcement component with the first portion of the heated press comprises engaging a press surface of the reinforcement component with an intermediate insert complementarily configured with respect to the press surface, the press surface opposing the faying surface of the reinforcement component, the intermediate insert having a planar first surface engageable with a planar surface of the first portion and an opposing second surface engageable with and conformal to the reinforcement component such that the pressure applied to the reinforcement component and the panel component, between the first and second portions, is evenly distributed across the reinforcement component.

Optionally, heating the first and second portions of the press to the curing temperature associated with the panel component comprises heating the first and second portions of the press to the curing temperature associated with the panel component, the curing temperature being less than a curing temperature associated with the reinforcement component.

Optionally, engaging the reinforcement component with the first portion of the heated press comprises engaging the reinforcement component having a cross-section that is shaped as a "bell", a "hat", an "I", a "J", or a "T" with the first portion of the heated press.

Optionally, the method further comprises molding or stamping a material to form the reinforcement component before engaging the formed reinforcement component with the first portion of the heated press.

Optionally, the method further comprises collating uncured plies of the panel component before engaging at least one of the plies with the second portion of the press.

There is further described herein an apparatus for forming a reinforced panel, the apparatus comprising: a first planar platen having a planar surface; a second planar platen having a planar surface adapted to engage a panel component, the second planar platen being co-operable with the first planar platen to apply a pressure therebetween; and an intermediate insert adapted to engage a reinforcement component, the intermediate insert having a planar first surface engageable with the planar surface of the first or second planar platen and an opposing second surface engageable with and conformal to the reinforcement component such that the pressure applied to the reinforcement component and the panel component, between the first and second planar platen, is evenly distributed across the reinforcement component, wherein at least the intermediate insert and both the first and second planar platen are heated.

Optionally, the reinforcement component comprises a thermoplastic or thermoset stiffener and the panel component comprises a thermoset skin.

Optionally, the reinforcement component is a thermoplastic stiffener.

Optionally, the reinforcement component is a thermoset stiffener.

These and other features, examples, and advantages of the present disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements set forth in this disclosure or recited in any one or more of the claims, regardless of whether such features or elements are expressly combined or otherwise recited in a specific example description or claim herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosure, in any of its examples, should be viewed as intended to be combinable, unless the context of the disclosure clearly dictates otherwise.

Having thus described examples of the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:.

Some examples of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all examples of the disclosure are shown. Indeed, various examples of the disclosure may be embodied in many different forms and should not be construed as limited to the examples set forth herein; rather, these examples are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. For example, unless otherwise indicated, reference to something as being a first, second or the like should not be construed to imply a particular order. Also, something described as being above something else (unless otherwise indicated) may instead be below, and vice versa; and similarly, something described as being to the left of something else may instead be to the right, and vice versa.

Examples of the present disclosure are generally directed to a method of forming a reinforced panel component and a related apparatus. As illustrated in <FIG>, for example, a reinforced panel component <NUM> is formed using the method and apparatus disclosed herein. The reinforced panel component <NUM> comprises, in particular examples, a cross-section having a size / shape dependent upon its application in the aircraft structure. For example, the reinforced panel component <NUM> comprises a cross-section defining a channel with or without a flange (e.g., a "bell" shape or a "hat" shape), a hook or a "J" shape, or one or more vertical or horizontal components (e.g., a vertical component sandwiched between two horizontal components or an "I" shape, a vertical component having a horizontal component at one end or a "T" shape); although any other shapes, sizes, types, etc., are contemplated by examples of the present disclosure. As illustrated in <FIG>, the reinforced panel component is a hat-shaped reinforced panel component formed by simultaneously or substantially simultaneously co-bonding faying surfaces of a reinforcement component and panel component together, and curing the panel component, described in more detail as follows.

As used herein, a reinforcement component, in particular examples, is considered a composite reinforcement component, such as a composite stiffener, where the composite reinforcement component is formed by molding, stamping, etc., a composite material. The composite material of the reinforcement component is comprised of or includes a resin reinforced with a reinforcing material. Reinforcing materials comprise, but are not limited to, a manmade or natural fiber including carbon fiber, glass fiber, glass spheres, mineral fiber, or other reinforcing materials. If fibers are used as a reinforcing material, for example, the fibers are continuous or chopped, and are unidirectional, randomly-oriented, or in the form of a weave such as, but not limited to, a plain weave, a crowfoot weave, a basket weave, or a twill weave. The resin comprises, for example, thermoplastic materials that include, but are not limited to, polyphenylene sulfide, polyaryletherketone (PAEK), polyetherketoneketone (PEKK), polyetheretherketone (PEEK), polyimide, polyetherimide, polyamide, polyamide-imide, polyester, polybutadiene, polyurethane, polypropylene, polysulfone, polyethersulfone, polyphenylsulfone, polyacrylamide, polyketone, polyphthalamide, polyphenylene ether, polybutylene terephthalate, polyethylene, polyethylene terephthalate, polyester-polyarylate (e.g. VECTRAN®), polytetrafluoroethylene (PTFE), or other thermoplastic resins. Alternatively, the resin comprises, for example, thermoset materials that include, but are not limited to, epoxy resins, cyanate esters, benzoxazines, polyimides, bismaleimides, vinyl esters, polyurethanes, polyureas, polyurethane/polyurea blends, polyesters, or other thermoset resins. Likewise, a panel component, in particular examples, is considered a composite panel component, such as a composite skin panel, where the composite panel component is formed from one or more composite materials, comprised of or including a resin reinforced with a reinforcing material as described in reference to the reinforcement component, a matrix composite with polymer skin, a glass aluminum composite with polymer skin, or a titanium aluminum composite with polymer skin.

In some examples, the reinforcement component is considered a consolidated component while the panel component is considered a non-consolidated panel component. More particularly, simultaneously or substantially simultaneously co-bonding the respective faying surfaces of the reinforcement component and the panel component together, and curing the panel component (e.g., performing the co-bonding and the curing procedures simultaneously or substantially simultaneously), results in consolidation of the reinforcement component and the panel component to form the reinforced panel. A faying surface as used herein is one of two or more surfaces that are in direct or indirect contact with one another and are connected to one another through one or more of bolts, rivets, welding, soldering, bonding, etc..

Accordingly, the method and apparatus disclosed herein may advantageously reduce costs and/or cycle times associated with the formation of a lightweight and rigid reinforced panel component. In some examples, this is achieved through the utilization of a heated press with two platens co-operable with one another, which enables the reinforcement component and the panel component to be co-bonded with one another at respective faying surfaces while the panel component is cured (e.g., performing the co-bonding and the curing procedures simultaneously or substantially simultaneously). By doing so, the separate cycles of curing the panel component and then joining the reinforcement component and the cured panel component are combined into a single cycle using the heated press.

<FIG> illustrates an example of an apparatus in a closed position for forming a reinforced panel, the apparatus generally being designated as reference numeral <NUM>. In some examples, the reinforced panel is the reinforced panel <NUM> illustrated in <FIG>, or another type of reinforced panel in some other examples. Indeed, a reinforced panel of any size, shape, material, etc., is formable using the apparatus illustrated in <FIG>. In some examples, the apparatus <NUM> comprises a heated press having a first portion and an opposing second portion that are brought into engagement with one another (e.g., the first and second portions of the press moving between an open position and a closed position).

In some examples, the apparatus <NUM> comprises a first planar platen <NUM> or first portion having a planar surface <NUM>. A second planar platen <NUM> or second portion has a planar surface <NUM> adapted to engage a second component or a panel component <NUM>. In some examples, the panel component <NUM> is a composite thermoset skin panel comprised of a fiber (e.g., a carbon fiber, a particle, etc.) and a polymer resin matrix. Other composite materials of the panel component <NUM> are also contemplated. The thermoset skin is hardened by a curing process induced by heating the thermoset skin to a curing temperature, radiation, etc., and is promoted by high pressure.

More particularly, and in order to initiate curing the thermoset skin, the second planar platen <NUM> is co-operable with the first planar platen <NUM> so as to apply a pressure therebetween. For example, the two platens <NUM>, <NUM> are operably engaged with one another or brought into contact with one another (e.g., by concurrently operating each platen, operating only one platen, or operating each platen at different instances) so that a pressure is applied as a directional normal force on the platens (e.g., the first planar platen <NUM> exerts a normal force on the second planar platen <NUM>, and the second planar platen <NUM> exerts an opposing normal force on the first planar platen <NUM>). The pressure is between about <NUM> to about <NUM> MPa (about <NUM> to about <NUM> pounds per square inch (psi)), where the amount of normal force exerted, in some instances, is dependent on the surface area of the planar platen.

An intermediate insert or press member <NUM> is engageable with a reinforcement component <NUM>. In some examples, the reinforcement component <NUM> is a composite thermoplastic or thermoset composite stiffener. Where the reinforcement component is a composite thermoplastic reinforcement component, the composite thermoplastic reinforcement component softens when heated to a melting temperature associated with the composite thermoplastic material and then hardens when cooled.

The intermediate insert or press member <NUM> has a planar first surface or press surface <NUM> engageable with the planar surface <NUM>, <NUM> of the first or second planar platen <NUM>, <NUM> and an opposing second surface <NUM> engageable with and conformal to the reinforcement component <NUM>, such that the intermediate insert or press member <NUM> is considered complementarily configured with respect to the planar or press surface <NUM>, <NUM>. As illustrated in <FIG>, the planar first surface <NUM> of the intermediate insert <NUM> is engaged with the first planar platen <NUM>, while the second surface <NUM> is engaged with and conforms to the reinforcement component <NUM>. In particular, the second surface <NUM> of the intermediate insert <NUM> has a contour that corresponds to a contour of the reinforcement component <NUM>. For example, the contour of the reinforcement component <NUM> is based on the shape of the reinforcement component <NUM>, where the reinforcement component <NUM> has a cross-section that is shaped as a "bell", a "hat", an "I", a "J", or a "T", such that the second surface <NUM> has a contour that correspondingly receives the reinforcement component so shaped. Contouring the second surface <NUM> of the intermediate insert <NUM> advantageously results in that the pressure applied to the reinforcement component <NUM> and the panel component <NUM>, between the first and second planar platens <NUM>, <NUM>, may be evenly distributed across the reinforcement component <NUM>. The apparatus <NUM> may further include one or more heating element <NUM> which is associated with either one of, two of, or all of the intermediate insert <NUM>, the first planar platen <NUM>, and/or the second planar platen <NUM>. In some examples, the apparatus <NUM> includes a heating element <NUM> associated with at least the intermediate insert <NUM> and the first or second planar platen <NUM>, <NUM>. The one or more heating element <NUM> may be arranged to heat either one of, two of, or all of the intermediate insert <NUM>, the first planar platen <NUM>, and/or the second planar platen <NUM> to simultaneously or substantially simultaneously co-bond the reinforcement component <NUM> and the panel component <NUM> together, cure the panel component <NUM>, and form a reinforced panel (e.g., <NUM>, <FIG>). In some examples, the heating element <NUM> is arrangeable to heat at least the intermediate insert <NUM> and the first or second platen <NUM>, <NUM> to simultaneously or substantially simultaneously co-bond the reinforcement component <NUM> and the panel component <NUM> together, cure the panel component <NUM>, and form a reinforced panel (e.g., <NUM>, <FIG>).

In some examples, the intermediate insert <NUM> and the first and/or second platen <NUM>, <NUM> is heated through an electrical connection with a power source (not shown) of the apparatus <NUM>, while the intermediate insert <NUM> and the first and/or second platen <NUM>, <NUM> are operably engaged with one another and are under pressure. For example, actuation of the power source directs electrical current to the heating element <NUM>, such as for example a heat rod, embedded in, integrated with, or otherwise associated with the intermediate insert <NUM> and/or the first and/or second platen <NUM>, <NUM>. The intermediate insert <NUM> and the first and/or second platen <NUM>, <NUM> are then heated by the heating element <NUM> to a curing temperature associated with the panel component <NUM> (for example, a pre-determined or given temperature known to cure the panel component <NUM>). The curing temperature of the panel component <NUM> depends on the material of the panel component, where different materials have different curing temperatures. In some examples, the intermediate insert <NUM> and the first or second platen <NUM>, <NUM> is heated to a curing temperature between about <NUM> (about <NUM> degrees Fahrenheit (°F)) and about <NUM> (about <NUM> °F) for between about <NUM> minutes and about <NUM> minutes, where the panel component is a composite thermoset, so as to simultaneously or substantially simultaneously co-bond respective faying surfaces <NUM>, <NUM> of the reinforcement component <NUM> and the panel component <NUM> together, cure the panel component <NUM>, and form the reinforced panel. The curing temperature associated with the panel component <NUM> is a temperature that is less than a melting temperature associated with the reinforcement component <NUM>. In this manner, heating the panel component <NUM> and the reinforcement component <NUM> does not melt the reinforcement component while the panel component <NUM> is cured.

In some examples, the reinforcement component <NUM> is treated prior to the first and second planar platens <NUM>, <NUM> being operably engaged. More particularly, the faying surface <NUM> of the reinforcement component <NUM> and/or the faying surface <NUM> of the panel component <NUM> is treated through application of a film, an energetic surface preparation, and the like so that the faying surface <NUM>, <NUM> is active for co-bonding with respect to the panel component <NUM>. The type of preparation treatment applied to the faying surface(s) <NUM>, <NUM> depends on the material of the reinforcement component <NUM>.

In some examples, where the reinforcement component <NUM> is a composite thermoplastic reinforcement component, a thermoplastic film <NUM> is applied on the faying surface <NUM> of the thermoplastic reinforcement component such that the faying surface <NUM> is active for co-bonding with respect to the panel component <NUM>. The thermoplastic film <NUM> comprises at least one of a polyetherimide (PEI), a polyphenylene sulfide, a polyimide, a polyamide, a polyamide-imide, a polyester, a polybutadiene, a polyurethane, a polypropylene, a polysulfone, a polyethersulfone, a polyphenylsulfone, a polyacrylamide, a polyketone, a polyphthalamide, a polyphenylene ether, a polybutylene a terephthalate, a polyethylene, a polyethylene terephthalate, a polyester-polyarylate, a polytetrafluoroethylene (PTFE), or any combination thereof.

In other examples, where the reinforcement component <NUM> is a composite thermoset reinforcement component, an adhesive promoter film <NUM> is applied on the faying surface <NUM> of the composite thermoset reinforcement component <NUM> and/or an energetic surface preparation <NUM> is performed on the faying surface <NUM> of the composite thermoset reinforcement component <NUM> such that the faying surface <NUM> is active for co-bonding with respect to the panel component <NUM>. The adhesive promoter film comprises unfilled, partially advanced epoxy resin. The energetic surface preparation comprises performing a corona treatment, a plasma treatment, a flame treatment, or the like on the faying surface <NUM> of the composite thermoset reinforcement component <NUM> such that the faying surface <NUM> is active for co-bonding with respect to the panel component <NUM>.

In some examples, a suction mechanism (not shown) is utilized in order to apply suction to the apparatus <NUM> to remove any air or volatiles trapped in the uncured panel component <NUM>. Removal of air or volatiles ensures a strong co-bond between the reinforcement component <NUM> and the panel component <NUM>. Any air or volatiles may prevent a strong and secure co-bond at the faying surfaces <NUM>, <NUM>.

Accordingly, the apparatus illustrated in <FIG>, provides for the reinforcement component <NUM> and the panel component <NUM> to be co-bonded while the panel component <NUM> is cured. The time period for doing so is, in some examples, shorter than conventional joining methods, such that significant cost savings and/or efficiency may be realized.

<FIG> illustrates an example of a method of forming a reinforced panel, where the method is generally indicated by the reference numeral <NUM>. In some instances, the reinforced panel is a panel such as that illustrated in <FIG>. Further, the method <NUM> is performed using an apparatus, such as the apparatus <NUM> in <FIG>.

In step <NUM>, molding (e.g., continuous compression molding (CCM)) or stamping a material is performed to form a reinforcement component (e.g., element <NUM> in <FIG>). In step <NUM>, collating uncured plies of a panel component (e.g., element <NUM> in <FIG>) is performed. In step <NUM>, the apparatus (e.g., a heated press such as the apparatus <NUM> in <FIG>) is pre-heated to a pre-heated temperature, the pre-heated temperature being less than a curing temperature associated with the panel component. For example, the press is pre-heated to between about <NUM> (about <NUM> °F) and about <NUM> (about <NUM> °F).

In step <NUM>, the reinforcement component is engaged with a first portion (e.g., element <NUM> in <FIG>) of the heated press, the reinforcement component having a faying surface. In step <NUM>, the uncured panel component is engaged with an opposing second portion (e.g., element <NUM> in <FIG>) of the press, the panel component having a faying surface complementarily-configured with respect to the faying surface of the reinforcement component. In step <NUM>, the faying surface of the reinforcement component is treated such that the faying surface is active for co-bonding. Notably, step <NUM> is optional and is dependent on the material of the reinforcement component.

In step <NUM>, suction is applied to the press to remove any air or volatiles trapped in the uncured panel component. In step <NUM>, the press is actuated to direct the first and second portions of the press toward each other, such that the faying surfaces of the reinforcement component and the panel component are complementarily engaged under pressure. In step <NUM>, the first and second portions of the press is heated to the curing temperature associated with the panel component to simultaneously or substantially simultaneously co-bond the faying surfaces of the reinforcement component and the panel component together, cure the panel component, and form the reinforced panel.

A still further method of forming a reinforced component is provided in <FIG>, the method generally referred to by the reference numeral <NUM>. The reinforced component is a panel such as that illustrated in <FIG>. The method <NUM> is performed using an apparatus, such as the apparatus <NUM> in <FIG>.

In a first step, <NUM>, a first component formed of a consolidated material is positioned on a first side of a heated press, the consolidated material having a faying surface. In a second step, <NUM>, a second component formed of a non-consolidated material is positioned on an opposing second side of the heated press, the non-consolidated material having a faying surface complementarily-configured with respect to the faying surface of the consolidated material. In a third step, <NUM>, the faying surface of the consolidated material is treated such that the faying surface is active for co-bonding with respect to the non-consolidated material. In a fourth step, <NUM>, the press is actuated to direct the first and second sides of the press toward each other, such that the faying surfaces of the consolidated material and the non-consolidated material are complementarily engaged under pressure. In a fifth step, <NUM>, the first and second sides of the press is heated to a curing temperature associated with the non-consolidated material to simultaneously or substantially simultaneously co-bond the faying surfaces of the consolidated material and the non-consolidated material together, cure the non-consolidated material, and form the reinforced component.

In some examples, actuating the press to direct the first and second sides of the press toward each other comprises applying a pressure of between about <NUM> to about <NUM> MPa (about <NUM> to about <NUM> pounds per square inch (psi)) to the consolidated material and the non-consolidated material between the first and second sides of the press.

In some further examples, heating the first and second sides of the press to the curing temperature comprises heating the first and second sides of the press to between about <NUM> (about <NUM> °F) and about <NUM> (about <NUM> °F) for between about <NUM> minutes and about <NUM> minutes so as to simultaneously or substantially simultaneously co-bond the faying surfaces of the consolidated material and the non-consolidated material together, cure the non-consolidated material, and form the reinforced component.

Claim 1:
A method of forming a reinforced panel (<NUM>), the method comprising:
engaging a reinforcement component (<NUM>) with a first portion (<NUM>) of a heated press, the reinforcement component (<NUM>) having a faying surface (<NUM>);
engaging an uncured panel component (<NUM>) with an opposing second portion (<NUM>) of the press, the panel component (<NUM>) having a faying surface (<NUM>) complementarily-configured with respect to the faying surface (<NUM>) of the reinforcement component (<NUM>);
treating the faying surface (<NUM>) of the reinforcement component (<NUM>) such that the faying surface (<NUM>) is active for co-bonding with respect to the panel component (<NUM>);
actuating the press to direct the first and second portions (<NUM>,<NUM>) of the press toward each other, such that the faying surfaces (<NUM>,<NUM>) of the reinforcement component (<NUM>) and the panel component (<NUM>) are complementarily engaged under pressure; and
heating the first and second portions (<NUM>,<NUM>) of the press to a curing temperature associated with the panel component (<NUM>) to simultaneously or substantially simultaneously co-bond the faying surfaces (<NUM>,<NUM>) of the reinforcement component (<NUM>) and the panel component (<NUM>) together, cure the panel component (<NUM>), and form the reinforced panel (<NUM>); and wherein
engaging the reinforcement component (<NUM>) with the first portion (<NUM>) of the heated press comprises engaging a press surface of the reinforcement component (<NUM>) with an intermediate insert (<NUM>) complementarily configured with respect to the press surface, the press surface opposing the faying surface (<NUM>) of the reinforcement component (<NUM>), the intermediate insert (<NUM>) having a planar first surface (<NUM>) engaging with a planar surface (<NUM>) of the first portion (<NUM>) and an opposing second surface (<NUM>) engaging with and conformal to the reinforcement component (<NUM>) such that the pressure applied to the reinforcement component (<NUM>) and the panel component (<NUM>), between the first and second portions (<NUM>,<NUM>), is evenly distributed across the reinforcement component (<NUM>).