# US 11,298,870 B2 · Methods for forming composite panels > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,298,870 B2 - Document ID: US11298870B2 - Status: Granted - Kind: B2 - Application number: 16/794,619 - Filed: 2020-02-19 - Published: 2021-08-19 - Granted: 2022-04-12 - Earliest claimed: 2020-02-19 - Assignees: The Boeing Company - Applicants: The Boeing Company - Inventors: Karen L. Hills; Lon E. Switzer - Web page: https://patentgrep.com/patent/US11298870B2 ## CPC - B29C 63/04: by folding, winding, bending or the like - B29C 63/0017: {characterised by the choice of the material} - B29C 63/0065: {Heat treatment} - B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material} - B32B 5/145: {Variation across the thickness of the layer} - B32B 2262/106: Carbon fibres, e.g. graphite fibres - B32B 2398/20: Thermoplastics - B32B 2605/18: Aircraft - B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract A method of forming a composite panel includes providing an initial composite material, heating the initial composite material, molding the initial composite material to form a preliminary composite panel having a main body connected to an outer edge and a laminate layer secured to the outer edge, and folding an exterior edge portion of the outer edge over an interior edge portion to provide an external folded edge having the laminate layer on at least a portion of an outer surface. ## Claims ### Claim 1 A method of forming a composite panel, comprising: providing an initial composite material; heating the initial composite material; molding the initial composite material to form a preliminary composite panel having a main body connected to an outer edge and a laminate layer secured to the outer edge; and folding an exterior edge portion of the outer edge over an interior edge portion to provide an external folded edge having the laminate layer on at least a portion of an outer surface. ### Claim 2 (depends on 1) The method of claim 1, wherein said folding comprises folding the exterior edge portion along a groove between the exterior edge portion and the interior edge portion. ### Claim 3 (depends on 1) The method of claim 1, wherein said providing comprises forming the initial composite material of a thermoplastic matrix and carbon fibers. ### Claim 4 (depends on 3) The method of claim 3, wherein the carbon fibers are recycled. ### Claim 5 (depends on 1) The method of claim 1, wherein said heating comprises heating the initial composite material to a temperature within a range between 500−650° F. ### Claim 6 (depends on 1) The method of claim 1, wherein said molding comprises co-molding the preliminary composite panel along with the laminate layer. ### Claim 7 (depends on 1) The method of claim 1, wherein the main body has a first thickness, and the outer edge has a second thickness, and wherein the first thickness is greater than the second thickness. ### Claim 8 (depends on 7) The method of claim 7, wherein the first thickness is twice the second thickness. ### Claim 9 (depends on 1) The method of claim 1, wherein said molding further comprises forming a groove in the outer edge. ### Claim 10 (depends on 9) The method of claim 9, wherein said forming the groove comprises forming the groove between the interior edge portion and the exterior edge portion. ### Claim 11 (depends on 10) The method of claim 10, wherein said forming the groove further comprises forming the groove proximate to the laminate layer. ### Claim 12 (depends on 1) The method of claim 1, wherein said folding comprises rolling the exterior edge portion of the outer edge onto the interior edge portion. ### Claim 13 (depends on 1) The method of claim 1, wherein said folding provides the external folded edge having a same thickness as the main body. ### Claim 14 (depends on 1) The method of claim 1, further comprising subsequently compressing the composite panel after said folding. ### Claim 15 A method of forming a composite panel, comprising: providing an initial composite material, wherein said providing comprises forming the initial composite material of a thermoplastic matrix and carbon fibers; heating the initial composite material; molding the initial composite material to form a preliminary composite panel having a main body connected to an outer edge and a laminate layer secured to the outer edge, wherein said molding comprises co-molding the preliminary composite panel along with the laminate layer; folding an exterior edge portion of the outer edge over an interior edge portion to provide an external folded edge having the laminate layer on at least a portion of an outer surface, wherein said folding comprises folding the exterior edge portion along a groove between the exterior edge portion and the interior edge portion; and subsequently compressing the composite panel after said folding. ### Claim 16 (depends on 15) The method of claim 15, wherein the carbon fibers are recycled. ### Claim 17 (depends on 15) The method of claim 15, wherein said heating comprises heating the initial composite material to a temperature within a range between 500−650° F. ### Claim 18 (depends on 15) The method of claim 15, wherein the main body has a first thickness, and the outer edge has a second thickness, and wherein the first thickness is greater than the second thickness. ### Claim 19 (depends on 15) The method of claim 15, wherein said molding further comprises forming a groove in the outer edge, wherein said forming the groove comprises forming the groove between the interior edge portion and the exterior edge portion, and wherein said forming the groove further comprises forming the groove proximate to the laminate layer. ### Claim 20 (depends on 15) The method of claim 15, wherein said folding further comprises rolling the exterior edge portion of the outer edge onto the interior edge portion, and wherein said folding provides the external folded edge having a same thickness as the main body.