Multifunctional surfacing materials for use in composite structures are disclosed. According to one embodiment, the surfacing material includes (a) a stiffening layer, (b) a curable resin layer, (c) a conductive layer, and (d) a nonwoven layer, wherein the stiffening layer (a) and the nonwoven layer (d) are outermost layers, and the exposed surfaces of the outermost layers are substantially tack-free at room temperature (20° C. to 25° C.). The conductive layer may be interposed between the curable resin layer and the stiffening layer or embedded in the curable resin layer. According to another embodiment, the surfacing material includes a fluid barrier film between two curable resin layers. The surfacing materials may be in the form of a continuous or elongated tape that is suitable for automated placement.

A composite roof panel of a vehicle disposed vertically above a passenger cabin of the vehicle includes: a first one or more layers of carbon fiber; a second one or more layers of carbon fiber; a binder material configured to bind the first and second one or more layers of carbon fiber; first and second electrical conductors that are: disposed between the first one or more layers of carbon fiber and the second one or more layers of carbon fiber; configured to be selectively electrically connected to a battery of the vehicle; and electrically connected to at least one of the first and second one or more layers of carbon fiber.

A composite roof panel of a vehicle disposed vertically above a passenger cabin of the vehicle includes: a first one or more layers of carbon fiber; a second one or more layers of carbon fiber; a binder material configured to bind the first and second one or more layers of carbon fiber; first and second electrical conductors that are: disposed between the first one or more layers of carbon fiber and the second one or more layers of carbon fiber; configured to be selectively electrically connected to a battery of the vehicle; and electrically connected to at least one of the first and second one or more layers of carbon fiber.

A grid and skin assembly for use in a composite laminate structure is described. The assembly includes a metallic grid having a plurality of intersecting ribs oriented in at least two distinct rib directions offset at a grid angle relative to one another and defining respective intersection points; and a composite laminate skin having a plurality of ply layers comprising a plurality of tapes oriented in at least two distinct tape directions offset at a ply angle relative to one another. The grid angle is at least 25 degrees, the intersection points define glueless joints of the metallic grid, and the grid is a non-aluminum-based material. A grid and method of manufacturing the grid and skin assembly is also described. The method includes a water jet cutting procedure and glueless joint formation due to differing thermal expansion characteristics of the grid and skin.

A grid and skin assembly for use in a composite laminate structure is described. The assembly includes a metallic grid having a plurality of intersecting ribs oriented in at least two distinct rib directions offset at a grid angle relative to one another and defining respective intersection points; and a composite laminate skin having a plurality of ply layers comprising a plurality of tapes oriented in at least two distinct tape directions offset at a ply angle relative to one another. The grid angle is at least 25 degrees, the intersection points define glueless joints of the metallic grid, and the grid is a non-aluminum-based material. A grid and method of manufacturing the grid and skin assembly is also described. The method includes a water jet cutting procedure and glueless joint formation due to differing thermal expansion characteristics of the grid and skin.

A method of fabricating a panel includes laying up a first laminate on a tooling surface, laying a first layer of thermoplastic on an inner surface of the first laminate, laying a large cell carbon core on the first layer of thermoplastic, laying a second layer of thermoplastic across the large cell carbon core, laying a second laminate on the second layer of thermoplastic, creating a sealed core pocket by bonding the edges of the first and second layers of the thermoplastic surrounding a perimeter of the core, increasing pressure within the core pocket, increasing pressure on the outer surface of the second laminate, heating the panel to a desired curing temperature, and maintaining the increased pressures and temperature for a desired curing duration.

A method of fabricating a panel includes laying up a first laminate on a tooling surface, laying a first layer of thermoplastic on an inner surface of the first laminate, laying a large cell carbon core on the first layer of thermoplastic, laying a second layer of thermoplastic across the large cell carbon core, laying a second laminate on the second layer of thermoplastic, creating a sealed core pocket by bonding the edges of the first and second layers of the thermoplastic surrounding a perimeter of the core, increasing pressure within the core pocket, increasing pressure on the outer surface of the second laminate, heating the panel to a desired curing temperature, and maintaining the increased pressures and temperature for a desired curing duration.

Disclosed are laminates comprising a carbon fiber reinforced polymer sheet and a layer of polysilazane and methods for producing such laminates.

Disclosed are laminates comprising a carbon fiber reinforced polymer sheet and a layer of polysilazane and methods for producing such laminates.

Embodiments of the present invention may encompass gateline paddles that include a paddle body having a composite material forming an outer surface of the paddle body. The composite material may have a first surface and a second surface opposite the first surface that define an open interior therebetween. The composite material may include a fiber-reinforced resin. The paddle body may include a cellular reinforcement member disposed within the open interior. The paddle body may include a mounting region formed along a lateral edge of the paddle body. The paddle body may include a mounting block disposed within a portion of the open interior disposed within the mounting region.