Composite structures and methods of forming composite structures are provided. The composite structures can include one or more composite structure components. Each composite structure component is formed from a composite panel that includes one or more sheets of material. The sheets of material include a thermoplastic material and a plurality of reinforcing fibers. A composite panel can be formed in three dimensions to form a composite structure component. Multiple composite structure components can be fused to one another to form a composite structure. In addition, each composite structure component and the composite structure formed therefrom can include an aperture. An interior volume can be formed between adjacent composite structure components. Methods for forming a composite structure can include a step of simultaneously molding and fusing composite structure components.

A multifunctional fully integral panel system design, a unique material configuration, and a process for fabricating a net shape (or nearly net shape) panel in one production cycle. The panel may comprise a base facing with an outer perimeter, a decorative film applied to the exterior of the base facing, an aft facing having an outer perimeter fused to the base facing, and a reinforcement core disposed between the unfused portions of the base and aft facings, which reinforcement core also acts as acoustic insulation (i.e., a noise attenuator). Alternatively or additionally, a foam core or blanket having thermal and/or acoustic insulation properties is attached to the external surface of the aft facing. The fabrication process involves the application of different heat treatments to panel components having different forming temperature or rubbery/elastic plateaus.

A multifunctional fully integral panel system design, a unique material configuration, and a process for fabricating a net shape (or nearly net shape) panel in one production cycle. The panel may comprise a base facing with an outer perimeter, a decorative film applied to the exterior of the base facing, an aft facing having an outer perimeter fused to the base facing, and a reinforcement core disposed between the unfused portions of the base and aft facings, which reinforcement core also acts as acoustic insulation (i.e., a noise attenuator). Alternatively or additionally, a foam core or blanket having thermal and/or acoustic insulation properties is attached to the external surface of the aft facing. The fabrication process involves the application of different heat treatments to panel components having different forming temperature or rubbery/elastic plateaus.

The disclosure relates to forming shaped thermoplastic articles having smooth peripheries. Many thermoplastic articles have sharp edges formed upon molding or cutting the article from a feedstock sheet. Such sharp edges can damage thin plastic films or flesh which they contact, and smoothing the edges is desirable. Described herein are methods of forming a smooth periphery for such sharp-edged articles by rolling over the sharp edge. The smoothing operation is performed by forming a deflectable flange including a bend region separated from the potentially sharp peripheral edge by a spacer, deflecting a portion of the deflectable flange, and softening at least one bent portion of the deflectable flange to yield a smooth periphery upon cooling.

A method of forming a decorative article comprising placing a decorative cover sheet comprising an untextured skin layer, a cushion foam layer and an adhesive layer in a mold space between a front mold half and a rear mold half, placing a substrate on the rear mold half, heating a textured front mold surface and the skin layer with a first heater arrangement between the front mold half and the cover sheet, heating the cover sheet and the substrate with a second heater arrangement between the cover sheet and the rear mold half, forming the skin layer of the decorative cover sheet into contact with the textured front mold surface, forming into the skin layer a textured surface from the textured front mold surface, pressing the substrate against the adhesive layer of the decorative cover sheet, and bonding the cover sheet to the substrate with the adhesive layer.

A hollow container producing device for producing a hollow container using a pair of parison sheets is provided. The hollow container producing device includes a pair of molds; an intermediate frame to be clamped to the pair of molds; and a transport unit that carries the intermediate frame and a pair of parison sheets to a position between the pair of molds, with the pair of parison sheets being respectively held on opposite sides of the intermediate frame.

A hollow container producing device for producing a hollow container using a pair of parison sheets is provided. The hollow container producing device includes a pair of molds; an intermediate frame to be clamped to the pair of molds; and a transport unit that carries the intermediate frame and a pair of parison sheets to a position between the pair of molds, with the pair of parison sheets being respectively held on opposite sides of the intermediate frame.

A method and an apparatus for making a non-woven fabric article are provided. The method includes providing a screen mold, disposing a formable material thereover, and evacuating air from the screen mold. The screen mold is made of a non-pliable material, and has an annular surrounding wall that defines an internal space, and multiple screen holes that extend through the annular surrounding wall and communicate with the internal space. The formable material is disposed over the annular surrounding wall and the screen holes of the screen mold, and then air is evacuated from the internal space via a suction device to form the fabric article.

Continuous adjustment appliances are provided that can store a large number of geometries that can be successively accessed throughout orthodontic treatment, with each geometry can correspond to an arrangement of the patient's teeth. An appliance according to the present disclosure can be stimulated to transition among the myriad geometries, which can include changes to the overall shape of the appliance as well as the position and geometry of the cavities corresponding to a patient's teeth. Methods of creating the continuous adjustment appliances and methods of treatment using the continuous adjustment appliances are also revealed.

Continuous adjustment appliances are provided that can store a large number of geometries that can be successively accessed throughout orthodontic treatment, with each geometry can correspond to an arrangement of the patient's teeth. An appliance according to the present disclosure can be stimulated to transition among the myriad geometries, which can include changes to the overall shape of the appliance as well as the position and geometry of the cavities corresponding to a patient's teeth. Methods of creating the continuous adjustment appliances and methods of treatment using the continuous adjustment appliances are also revealed.