The Boeing Company

Jeffrey T Wirrick

Michael John Cloud

Disclosed herein is a molded laminated structure having negative draft angles and methods of manufacturing a molded laminated structure having negative draft angles. A preliminary structure having a first outer layer and a second outer layer is molded with a bend that divides the preliminary structure into two sections with an angle between the two sections of less than 180-degrees. Portions that extends from the sections are at positive draft angles. A groove is formed in the preliminary structure at the bend but not formed in a constant cross-section of the second outer layer. The preliminary structure is folding along the bend to at least partially close the groove and form a molded laminated structure with portions that extend at a negative draft configuration while retaining the second outer layer continuous throughout the molded laminated structure.

Molded laminated structure with negative draft angles and associated methods of manufacturing

A method of manufacturing a protective cover () for a component of a vehicle includes assembling multiple layers to form a charge (). The charge () is formed within a mold () of the component to form a multi-contoured laminate (). The protective cover () is separated from the multi-contoured laminate (). A method of forming a down stream part structure or mold () for a component includes assembling multiple layers to form a charge (). The charge () is formed within an original mold of the component to form a multi-contoured laminate (). A splash is separated from the multi-contoured laminate (). A protective cover, such as the cover (), is for a vehicle component and includes a contour holding layer () and a protective laminate layer (). The contour holding layer () and the protective laminate layer () are formed within a mold of the vehicle component to form the protective cover.

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Bothell, WA, United States of America

Jeffrey T Wirrick