A method of manufacturing thermoplastic structures wherein the structure comprises a fiber-reinforced thermoplastic resin. The fiber reinforcement may be in the form of a woven or non-woven web. The thermoplastic resin may be introduced therein in the form of staple fibers blended into the non-woven web or by melt-coating the web or by laminating a pre-formed thermoplastic resin film to the web. The latter technique allows uniform distribution of a radar-absorbing material, coated on or blended into the pre-formed thermoplastic film, throughout the honeycomb.

Claims

76 · 4 independent · depth 5

76 granted claims

›1.independentA method of making a thermoplastic honeycomb structure comprising: (A) providing a longitudinally extending fiber-reinforced web comprising a thermopl…+21

›2.↳ 1The method according to claim 1, wherein said thermoplastic resin comprises thermoplastic resin fibers.d2+2

›4.↳ 1The method according to claim 1, wherein said fiber-reinforced web comprises fibers of a microwave radiation absorbent material.d2

›5.↳ 1The method according to claim 1, wherein said reinforcing fiber is inorganic.d2+1

›7.↳ 1The method according to claim 1, wherein said reinforcing fiber is organic.d2+1

›9.↳ 1The method according to claim 1, wherein said fiber-reinforced web comprises a lamination of a lamina of said woven web of said reinforcing fibers and…d2+5

›15.↳ 1The method according to claim 1, wherein said fiber-reinforced web further comprises staple fibers of a microwave radiation absorbent material.d2

›16.↳ 1The method according to claim 1, wherein said step (C) is effected by pressing between mating dies.d2

›17.↳ 1The method according to claim 1, wherein said step (C) is effected by vacuum forming.d2

›18.↳ 1The method according to claim 1, wherein a honeycomb structure is formed by melt-bonding said nodes and antinodes, which are in contact, to each other…d2

›19.↳ 1The method according to claim 1, wherein a honeycomb structure is formed by adhesively bonding said nodes and antinodes, which are in contact, to each…d2

›20.↳ 1The method according to claim 1, wherein said consolidation step (B) and said forming step (C) are effected simultaneously by a roller die which conso…d2

›21.↳ 1The method according to claim 1, wherein said longitudinally extending fibrous web is coated with a microwave radiation absorbent material.d2

›23.independentA method of making a thermoplastic honeycomb structure comprising: (A) providing a longitudinally extending fiber-reinforced web comprising a thermopl…+30

›24.↳ 23The method according to claim 23, wherein said thermoplastic resin comprises thermoplastic resin fibers.d2+2

›26.↳ 23The method according to claim 23, wherein said fiber-reinforced web comprises fibers of a microwave radiation absorbent material.d2

›27.↳ 23The method according to claim 23, wherein said reinforcing fiber is an organic fiber.d2+11

›28.↳ 27The method according to claim 27, wherein said organic fiber is cellulosic, polyaramid or polyamide fiber.d3

›29.↳ 27The method according to claim 27, wherein said fiber-reinforced web comprises an admixture of staple fibers of said thermoplastic resin and said reinf…d3+1

›31.↳ 27The method according to claim 27, wherein said fiber-reinforced web comprises a lamination of a lamina of said reinforcing fibers and at least one lam…d3+6

›32.↳ 31The method according to claim 31, wherein said laminate is produced by hot melt or extrusion coating a non-woven web of said reinforcing fibers with s…d4

›33.↳ 31The method according to claim 31, wherein said laminate is produced by melt-bonding a preformed film of said thermoplastic resin to a non-woven web of…d4

›34.↳ 31The method according to claim 31, wherein said lamina of said reinforcing fibers is sandwiched between a first lamina of said thermoplastic resin and …d4+1

›36.↳ 31The method according to claim 31, wherein said lamina of said thermoplastic resin comprises a preformed film of said thermoplastic resin and a microwa…d4+1

›47.↳ 27The method according to claim 27, wherein said fiber-reinforced web further comprises staple fibers of a microwave radiation absorbent material.d3

›38.↳ 23The method according to claim 23, wherein said reinforcing fiber is an inorganic fiber.d2

›39.↳ 23The method according to claim 23, wherein said first direction is substantially transverse to said second direction.d2

›40.↳ 23The method according to claim 23, wherein said at least one first fibrous non-woven web material is mechanically affixed to said at least one second f…d2+1

›42.↳ 23The method according to claim 23, wherein said at least one first fibrous non-woven web material is chemically affixed to said at least one second fib…d2+1

›44.↳ 23The method according to claim 23, wherein said at least one first fibrous non-woven web material is thermally affixed to said at least one second fibr…d2+1

›48.↳ 23The method according to claim 23, wherein said step (C) is effected by pressing between mating dies.d2

›49.↳ 23The method according to claim 23, wherein said step (C) is effected by vacuum forming.d2

›50.↳ 23The method according to claim 23, wherein a honeycomb structure is formed by melt-bonding said nodes and antinodes, which are in contact, to each othe…d2

›51.↳ 23The method according to claim 23, wherein a honeycomb structure is formed by adhesively bonding said nodes and antinodes, which are in contact, to eac…d2

›52.↳ 23The method according to claim 23, wherein said consolidation step (B) and said forming step (C) are effected simultaneously by a roller die which cons…d2

›53.↳ 23The method according to claim 23, wherein said longitudinally extending fibrous web is coated with a microwave radiation absorbent material.d2

›46.independentThe method according to claim F 38, wherein said first fibrous non-woven web material and said second fibrous non-woven web material each comprises an…

›55.independentA method of making a thermoplastic honeycomb structure comprising: (A) providing a longitudinally extending fiber-reinforced web comprising a thermopl…+21

›56.↳ 55The method according to claim 55, wherein said thermoplastic resin comprises thermoplastic resin fibers.d2+2

›58.↳ 55The method according to claim 55, wherein said fiber-reinforced web comprises fibers of a microwave radiation absorbent material.d2

›59.↳ 55The method according to claim 55, wherein said reinforcing fiber is inorganic.d2+1

›61.↳ 55The method according to claim 55, wherein said reinforcing fiber is organic.d2+1

›63.↳ 55The method according to claim 55, wherein said fiber-reinforced web comprises a lamination of a lamina of said unidirectionally oriented web of said r…d2+5

›69.↳ 55The method according to claim 55, wherein said fiber-reinforced web further comprises staple fibers of a microwave radiation absorbent material.d2

›70.↳ 55The method according to claim 55, wherein said step (C) is effected by pressing between mating dies.d2

›71.↳ 55The method according to claim 55, wherein said step (C) is effected by vacuum forming.d2

›72.↳ 55The method according to claim 55, wherein a honeycomb structure is formed by melt-bonding said nodes and antinodes, which are in contact, to each othe…d2

›73.↳ 55The method according to claim 55, wherein a honeycomb structure is formed by adhesively bonding said nodes and antinodes, which are in contact, to eac…d2

›74.↳ 55The method according to claim 55, wherein said consolidation step (B) and said forming step (C) are effected simultaneously by a roller die which cons…d2

›75.↳ 55The method according to claim 55, wherein said longitudinally extending fibrous web is coated with a microwave radiation absorbent material.d2

Classifications

6 codes

USPC · US Patent Classification

156/197428/116156/207156/242156/292156/208

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