Laminated parts are described that include a core, a fiber layer arranged on each side of the core and impregnated with a polyurethane resin, and an outer layer that at least partially coats at least one of the polyurethane impregnated fiber layers, in which the outer layer is the cured reaction product of a reaction mixture that includes: (1) a polyisocyanate, (2) a polyether polyol having a molecular weight of 800 Da to 25,000 Da and a functionality of 2 to 8, and (3) a fatty acid ester having isocyanate-reactive functionality. Methods of producing such laminated parts are also described.

A sandwich-type, composite component having a sprayed backside protective coating is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core positioned between and bonded to the outer layers and having a plurality of cavities. The protective coating is integrally formed from an elastomeric material. The material is sprayed to form the coating and the coating is bonded to the outer surface by curing. The component may be a vehicle interior component such as a vehicle load floor component.

A sandwich-type, composite component having a sprayed backside protective coating is provided. The component includes a first outer layer having an outer surface, a second outer layer and a core positioned between and bonded to the outer layers and having a plurality of cavities. The protective coating is integrally formed from an elastomeric material. The material is sprayed to form the coating and the coating is bonded to the outer surface by curing. The component may be a vehicle interior component such as a vehicle load floor component.

A flexible carbon fiber decorative veneer may include a veneer panel assembly with a face layer formed from a carbon fiber material, a backing layer formed from a flexible fleece, and an adhesive configured to attach the face layer to the backing layer through activation via at least one joining process. The backing layer may be configured to prevent light from passing through voids or interstitial spaces in the carbon fiber material of the face layer when the backing layer is attached to the face layer via the adhesive. The flexible carbon fiber decorative veneer may be configured for use on an aircraft interior structure, the base structure for which being fabricated from an aviation honeycomb layer and a back panel. The veneer panel assembly may be configured to conform to a radius of at least 0.25 inches on the aircraft interior structure.

A flexible carbon fiber decorative veneer may include a veneer panel assembly with a face layer formed from a carbon fiber material, a backing layer formed from a flexible fleece, and an adhesive configured to attach the face layer to the backing layer through activation via at least one joining process. The backing layer may be configured to prevent light from passing through voids or interstitial spaces in the carbon fiber material of the face layer when the backing layer is attached to the face layer via the adhesive. The flexible carbon fiber decorative veneer may be configured for use on an aircraft interior structure, the base structure for which being fabricated from an aviation honeycomb layer and a back panel. The veneer panel assembly may be configured to conform to a radius of at least 0.25 inches on the aircraft interior structure.

A method of manufacturing a lightweight building element assembly is disclosed. The assembly firstly comprises a first object (1) being a lightweight building element that has a first outer building layer (11) and an interlining layer (13). The assembly further comprises a second object (2) secured to the first object. The method comprises firstly providing the first object, wherein the first object has an indentation (19) formed by the first outer building layer. The indentation may form a blind opening or a through opening in the first object. The method further comprises providing the second object (2), wherein the second object comprises an outer surface portion of a thermoplastic material, wherein the outer surface portion is a lateral outer surface portion with respect to an axis. The second object is brought in contact with the first object so that the lateral outer surface is in physical contact with the sidewall (14), and mechanical energy is coupled into the second object so as to cause energy absorption due to friction between the lateral outer surface and the lateral wall, until a flow portion of the thermoplastic material becomes liquefiable and flows relative to the lateral wall. After re-solidification of the thermoplastic material, the flow portion secures the second object to the first object.

A method of manufacturing a lightweight building element assembly is disclosed. The assembly firstly comprises a first object (1) being a lightweight building element that has a first outer building layer (11) and an interlining layer (13). The assembly further comprises a second object (2) secured to the first object. The method comprises firstly providing the first object, wherein the first object has an indentation (19) formed by the first outer building layer. The indentation may form a blind opening or a through opening in the first object. The method further comprises providing the second object (2), wherein the second object comprises an outer surface portion of a thermoplastic material, wherein the outer surface portion is a lateral outer surface portion with respect to an axis. The second object is brought in contact with the first object so that the lateral outer surface is in physical contact with the sidewall (14), and mechanical energy is coupled into the second object so as to cause energy absorption due to friction between the lateral outer surface and the lateral wall, until a flow portion of the thermoplastic material becomes liquefiable and flows relative to the lateral wall. After re-solidification of the thermoplastic material, the flow portion secures the second object to the first object.

A structural board comprises a surface board and a bottom board. The bottom board comprises a first supporting surface and a second supporting surface, and the surface board is fixedly connected on the second supporting surface. The bottom board comprises a plurality of protruding cavities spaced apart from one another. Two end surfaces of each of the plurality of protruding cavities along a protruding direction of the plurality of protruding cavities respectively defines the first supporting surface and the second supporting surface. Each of a plurality of straight ribs is defined by two adjacent, spaced apart protruding cavities of the plurality of protruding cavities. Some of the plurality of straight ribs are connected together in an extending direction, and the plurality of straight ribs with different extending directions extend to be cross-connected to one another to form a polygonal mesh structure that defines the first supporting surface.

A structural board comprises a surface board and a bottom board. The bottom board comprises a first supporting surface and a second supporting surface, and the surface board is fixedly connected on the second supporting surface. The bottom board comprises a plurality of protruding cavities spaced apart from one another. Two end surfaces of each of the plurality of protruding cavities along a protruding direction of the plurality of protruding cavities respectively defines the first supporting surface and the second supporting surface. Each of a plurality of straight ribs is defined by two adjacent, spaced apart protruding cavities of the plurality of protruding cavities. Some of the plurality of straight ribs are connected together in an extending direction, and the plurality of straight ribs with different extending directions extend to be cross-connected to one another to form a polygonal mesh structure that defines the first supporting surface.

Disclosed is a first method of providing a heating system to an outer skin of an aircraft, that has the steps of forming laser-induced graphene (LIG) on a polymer sheet by directing laser energy towards the polymer sheet; coupling electrical leads to the LIG; and bonding the polymer sheet against the outer skin or erosion protection layer secured to the outer skin so that to the polymer sheet conforms with a shape of the outer skin.