IP Library › Granted Patent US 12,703,158
Granted Patent B2
US 12,703,158 · App. 18/231,402 · Granted Aug 11, 2026

Composite structures and methods of forming composite structures

Inventors: Matthew T. Giaraffa (Golden, CO); William B. Montague (Denver, CO)
Assignee: ASTRO TECH CO., LTD.
B29C70/465B29C33/505B29C70/081B29C70/44B29C70/46B32B3/266B32B27/08B32B27/34B29K2077/00B29K2101/12B29K2105/12B29K2307/04B29L2031/3091B32B2262/106B32B2605/00Y10T428/24273Y10T428/24322
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Quick Facts
Patent No.
US 12,703,158
App. No.
18/231,402
Granted
Aug 11, 2026
Kind
B2
Abstract

Composite structures and methods of forming composite structures are provided. The composite structures can include one or more composite structure components. Each composite structure component is formed from a composite panel that includes one or more sheets of material. The sheets of material include a thermoplastic material and a plurality of reinforcing fibers. A composite panel can be formed in three dimensions to form a composite structure component. Multiple composite structure components can be fused to one another to form a composite structure. In addition, each composite structure component and the composite structure formed therefrom can include an aperture. An interior volume can be formed between adjacent composite structure components. Methods for forming a composite structure can include a step of simultaneously molding and fusing composite structure components.

Claims (14)

1 . A structure, comprising:

a first composite structure component, including:

a plurality of sheets of thermoplastic material, wherein at least some of the sheets include a plurality of fibers;

an outside edge; and

an inside edge formed exclusively of the thermoplastic material alone, being continuous and formed in a closed loop; and

a second composite structure component, including:

a plurality of sheets of the thermoplastic material, wherein at least some of the sheets include a plurality of fibers;

an outside edge; and

an inside edge formed exclusively of the thermoplastic material alone, being continuous and formed in a closed loop,

wherein the inside edge of the first composite structure component is edge-to-edge welded to the inside edge of the second composite structure component, and the outside edge of the first composite structure component is edge-to-edge welded to the outside edge of the second composite structure component, forming welded joints; and

wherein an interior volume expands between adjacent interior surfaces of the first and second composite structure components and between the inside edges and the outside edges that are edge-to-edge welded.

2 . The structure of claim 1 , further comprising a first auxiliary aperture formed in the first composite structure component.

3 . The structure of claim 2 , further comprising a second auxiliary aperture formed in the second composite structure component.

4 . The structure of claim 3 , wherein the first auxiliary aperture is adjacent to the second auxiliary aperture.

Assignments (3)
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Feb 6, 2024
From: REVVED INDUSTRIES, LLC
To: ASTRO TECH CO., LTD.
Reel/Frame 066391/0341 →
CHANGE OF NAME Recorded Jan 11, 2024
From: GUERRILLA INDUSTRIES LLC
To: REVVED INDUSTRIES, LLC
Reel/Frame 066275/0001 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Nov 3, 2023
From: GIARAFFA, MATT; MONTAGUE, WILLIAM
To: GUERRILLA INDUSTRIES LLC
Reel/Frame 065445/0157 →
Continuity (4)
Continuation 17163957 · Feb 1, 2021
Continuation 15921410 · Mar 14, 2018
Provisional Application 62472397 · Mar 16, 2017
Related Publication 20240034008A1 · Feb 1, 2024
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