Methods, systems, and apparatuses are disclosed for the manufacture of composite components having incorporated reinforcing structures machined into composite material substrates, and composite components manufactured according to disclosed methods, and assemblies and larger structures comprising the composite material components.

Methods and apparatus to form venting channels on a panel for a decorative layer are disclosed. An example method includes contacting an outer surface of a tool to an outer resin layer of a panel. The outer surface of the tool has protrusions. The example method includes moving the outer surface of the tool on the outer resin layer of the panel in a first direction to cause the protrusions of the tool to form first venting channels on the outer resin layer of the panel and coupling a decorative layer to the outer resin layer of the panel via an adhesive layer. The first venting channels are to vent at least one of gas or vapor away from the decorative layer to deter separation of a portion of the decorative layer from the outer resin layer.

A ventilated structural panel comprising a first sheet, having a long axis defining a length and a perpendicular short axis defining a width, a plurality of spacing structural elements, fixedly attached to the first sheet such that the yield strength of the panel is greater than the individual yield strength of the first sheet, and the plurality of spacing structural elements being formed such that a plurality of unobstructed pathways are created for air to move from at least one edge of the panel to at least one of an opposite and an adjacent edge of the panel, wherein the first sheet is the only sheet in the panel.

A method of constructing a building comprising the steps of attaching a first panel to a second panel. The first panel is one of a single plenum panel and a multi-plenum panel and the second panel is one of a single plenum panel and a multi-plenum panel.

Methods and apparatus to form venting channels on a panel for a decorative layer are disclosed. An example method includes contacting an outer surface of a tool to an outer resin layer of a panel. The outer surface of the tool has protrusions. The example method includes moving the outer surface of the tool on the outer resin layer of the panel in a first direction to cause the protrusions of the tool to form first venting channels on the outer resin layer of the panel and coupling a decorative layer to the outer resin layer of the panel via an adhesive layer. The first venting channels are to vent at least one of gas or vapor away from the decorative layer to deter separation of a portion of the decorative layer from the outer resin layer.

A method for producing a sandwich panel with a reinforced foam core includes inserting rod-shaped, thermoplastic reinforcing elements into a thermoplastic foam material such that the reinforcing elements extend through the foam material. End regions of the reinforcing elements project out of the foam material. The foam material is thermoformed to form a reinforced foam core, wherein the end regions of the reinforcing elements are integrally formed by applying temperature and pressure to the cover surfaces of the foam material and are bonded to the foam material in a fused connection. A thermoplastic cover layer is laminated on either side by applying temperature and pressure to the reinforced foam core on the cover surfaces of the foam material in order to form the sandwich panel, wherein the cover layers are bonded to the reinforced foam core in a fused connection.

The object of the invention can be a method of manufacturing a product in the form of a sandwich comprising a core and outer layers. The outer layers may be composed of composite material comprising a fiber-reinforced polymeric matrix. The method uses an insert of heat-resistant material, for example silicone. The object of this invention can be to provide a method of manufacturing a sandwich that dissociates the choice of material of the core of the sandwich from the choice of the material of the outer layers.

Methods and apparatus to form venting channels on a panel for a decorative layer are disclosed. An example method includes contacting an outer surface of a tool to an outer resin layer of a panel. The outer surface of the tool has protrusions. The example method includes moving the outer surface of the tool on the outer resin layer of the panel in a first direction to cause the protrusions of the tool to form first venting channels on the outer resin layer of the panel and coupling a decorative layer to the outer resin layer of the panel via an adhesive layer. The first venting channels are to vent at least one of gas or vapor away from the decorative layer to deter separation of a portion of the decorative layer from the outer resin layer.

A method of manufacturing composite laminate panel sub-elements (34) for subsequent assembling into a modular assembly structure (37), comprises the preprocessing steps of casting an elongate composite laminate sheet panel (18) having opposite first and second fiber-reinforced plastic face skins (19,21) sandwiching a core (35), a free first elongate edge (22) and an opposite second elongate free edge (24), demolding the elongate composite laminate sheet panel (18), cutting the demolded elongate composite laminate sheet panel (18) into (n) shorter sections (Sn), thereby providing sections (Sn) with at least one free cut edge (26; 32), a free first edge (22) having the same profile as the free first elongate edge, and a free second edge (22) parallel to the free first edge and having the same profile as the free second elongate edge, and machining at least a first coupling profile (27) along the at least one free cut edge (26; 32).

Processes, systems, and methods described herein can be used for manufacturing reinforced carbon fiber structures. For example, processes can include forming a plurality of foam substructures. The foam substructures can be made of heat expanding foam that further expands when heated to a first threshold temperature. Processes can also include positioning carbon fiber on at least a portion of surfaces of the foam substructures, assembling the plurality of foam substructures with the carbon fiber into a superstructure, wrapping an outer surface of the superstructure with additional carbon fiber to form a wrapped superstructure, and curing the wrapped superstructure within a mold to form a reinforced carbon fiber structure. The reinforced carbon fiber structures can include internal truss structures within the foam. The reinforced carbon fiber structures can be used to form reinforced carbon fiber bicycle frame components.