Printed by Jouve, 75001 PARIS (FR)

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(11) EP 3 567 147 A2(12) EUROPEAN PATENT APPLICATION

(43) Date of publication: 13.11.2019 Bulletin 2019/46

(21) Application number: 19173641.2

(22) Date of filing: 09.05.2019

(51) Int Cl.:D04B 1/22 (2006.01)

(84) Designated Contracting States: AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TRDesignated Extension States: BA MEDesignated Validation States: KH MA MD TN

(30) Priority: 09.05.2018 US 201862669255 P

(71) Applicants: • Fabdesigns, Inc.

Malibu, CA 90265 (US)

• Huffa, BrucMalibu, CA 90265 (US)

• Huffa, Concetta MariaMalibu, CA 90265 (US)

(72) Inventors: • Huffa, Bruce

Malibu, CA California 90265 (US)• Huffa, Concetta Maria

Malibu, CA California 90265 (US)

(74) Representative: Dilg, Haeusler, Schindelmann Patentanwaltsgesellschaft mbHLeonrodstrasse 5880636 München (DE)

(54) METHOD OF MANUFACTURING A POLYMER REINFORCING PANEL AND A POLYMER REINFORCING PANEL

(57) A knitting method for knitting a polymer reinforc-ing panel structure to a shape as predefined for a finalproduct. Stiff materials in the form of knitting yarns areknitted on a V-bed weft knitting machine to create a pol-ymer reinforcing panel structure and any additional knit-ted textile elements with completely finished the edges.The resulting three-dimensional textile element is a uni-tary construction completed entirely by the knitting ma-chine in the knitting process, and is ready for a subse-quent polymer resin application and/or a molding proc-ess.

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Description

CROSSREFERENCE TO RELATED APPLICATION

[0001] This patent application claims priority and ben-efit of U. S. Provisional Patent Application No.62/669,255, entitled "METHOD FOR KNITTING CAR-BON FIBER VEHICLE COMPOSITE PANELS," filed onMay 09, 2018, the entire content of which is herein incor-porated by reference for all purposes.

TECHNICAL FIELD

[0002] Embodiments of the present disclosure relategenerally to mechanism of manufacturing fiber reinforcedpolymer composite panel structures, and more specifi-cally, to knitting mechanisms for fiber reinforced polymercomposite panel structures.

BACKGROUND OF THE INVENTION

[0003] A textile may be defined as any manufacturefrom fibers, filaments, or yarns characterized by flexibility,fineness, and a high ratio of length to thickness. The ma-terials forming composite polymer reinforcing panel maybe selected based upon the properties of wear-resist-ance, flexibility, stretch, surface friction, impact resist-ance, weight bearing properties, fracture toughness, andtensile strength for examples. One of the strongest, stiff-est, and more protective fibers is composite carbon fiber.Fiber reinforced polymerized plastic materials are agroup of composite materials which are made up of apolymer matrix reinforced with fibers. Combining thecharacteristics of the fibers or textile material and char-acteristics of the polymers, together form a new compos-ite material with physical properties exceeding those ofeither original material. Such composite materials areused in aerospace, automotive, sporting goods and con-sumer goods because their strength to weight ratio ex-ceeds all other known materials and material construc-tions.[0004] Composites materials are composed of two ormore chemically distinct materials, which, when com-bined, have improved properties over the original indi-vidual materials. FIG. 1 illustrates the composition of acomposite material. One of the materials is in a reinforc-ing phase 1, and the other is in a matrix phase 2, typicallya polymer or resin. The reinforcing phase material 1 isembedded in the matrix, for example: fibers, sheets, fab-rics, or particles. The fiber and/or filament reinforcementmaterial typically has high strength, high stiffness, andlow density and can be long or short fiber format. Exam-ples of reinforcement fibers are: carbon "graphene",glass S-glass, r-glass, hemp, jute, flax, boron, basalt, ce-ramics, metals, aramids, para-aramids and basalt. Thematrix material typically has good shear properties andlow density. Examples of matrix materials are polymersepoxides, polyesters, nylons, HDPE, etc., resins, metals

aluminum alloys, magnesium alloys, titanium, etc., andceramics SiC, glass ceramic, etc. There may also be aninterface for insuring bonding and/or surface adherence.Hundreds of types of resins are also available, each hav-ing specific chemical and physical characteristics. Themost commonly used are the polyester and epoxy fam-ilies. Various types of natural and synthetic fibers arecommercially available as well. For example: glass, car-bon, hemp, Kevlar®, flax, boron, linen, basalt, and ultra-high-molecular-weight- polyethylene UHMWPE.[0005] The resulting fiber reinforced polymer matrixcomposite 3 typically embodies properties superior toboth the matrix material and the reinforcement material,such as high strength to weight, high stiffness, goodshear properties and a low density. Fiber Reinforced Pol-ymer (FRP) composite materials are used in severaltypes of protective, performance vehicle, and sport craftsto provide the necessary stiffness, without adding a tre-mendous amount of weight. One reinforcing fiber mate-rial is carbon fiber, which frequently is used in makingvarious two-dimensional woven textile in aerospace, ar-chitecture, infrastructure, geotextiles, marine applica-tions, pipe and tank applications, sports and recreation,wind and solar energy. Automotives utilize a significantamount of composites for structural and aesthetic pur-poses in OEM and aftermarket vehicle parts. Compositesare frequently used in aerospace for functional, perform-ance, and protective purposes, some examples are heatresistance, stiffening, debris, corrosion, and impact pro-tection, high functionality performance in cold and ex-treme environments, extraordinarily high abrasion resist-ant characteristics, high durability, springiness whenmolded into a convex curves flex and recovery, shrinkresistance. In sports and recreation for example, two-dimensional woven FRP composites parts, specificallycomposite carbon fiber sheets, are cut, shaped and po-lymerized for use in body-protecting wearable products,including helmets and road armor for cycling, automotiveracing aerodynamic parts, shoe inserts, sole plates,shanks under the arch of the foot, heel counters, in por-tions of basketball shoes, hockey skates, and in runningshoes to minimize stretch and improve stability and re-sponsiveness of the article. Carbon fiber is considered apremium FRP material when incorporated into consumerproducts, due to the high-end costs of weaving, handling,cutting, polymerizing, and manufacturing componentsfrom two-dimensional sheets.[0006] From the perspective of manufacturing, the re-inforcement fibers in the composite may be unidirectional4, bi-directional 5, two-directional random 6, or three di-mensional random 7, depending on the orientation of thefibers. FIG. 2 shows different reinforcement fiber orien-tations in composite materials. In a unidirectional or onedirection composite, the reinforcing fibers are alignedsubstantially in one direction and in one plane on an X,Y, Z model. In a bi-directional composite, the reinforcingfibers are substantially aligned on one plane of an X, Y,Z model, but in two directions, sometimes perpendicular

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to each other. In a two-dimensional random composite,the reinforcing fiber material is substantially disposed onone plane of and X, Y, Z model, but may be in any direc-tion, including amorphous. In a three-dimensional ran-dom fiber reinforced composite structure, the fibers lie inmultiple directions and on multiple planes.[0007] Knitting can create a fifth form of fiber orienta-tion alignment. FIG. 3 illustrates a knit-reinforced com-posite.. As shown in FIG. 3, a complex distribution oflinked fibers 8 which reside in three dimensions, may belayered in the knitting process. Polymer 9 is added withthe fibers 8, and the resulting structure may be a thinsheet, a corrugation 10, or an article completely knittedto shape in one or more structures. Through knitting suchan article, the greatest density and alignment of fiber ten-sile strength can be placed where the most rigid perform-ance is required.[0008] The term weft knitting is used to describe theconstruction of fabric by feeding yarn and forming loopsin the horizontal "weft" direction. FIG. 5 shows the loopsand stitches formed in a weft knitting process. The termV-bed or flat-bed knitting describes weft knitting by feed-ing yarn and forming loops, with at least two opposingneedle beds, where latch needles and other elementsare selected and slide during the knitting process, to en-gage strands of material, to create a fabric. FIG. 4 showscommon carbon fiber weaves resulting from a knittingprocess. There is typically a technical textile face 11 anda technical textile back 12 to the fabric, and a grain, in-dicated by the direction of the loops in FIG. 5.[0009] In V-bed flat knitting, the needle beds are posi-tioned at an angle resembling a "V" shape. FIG. 6 showsthe needle beds and needles in a knitting machine. FIG.7 shows the configuration of two needle beds on a knittingmachine. Fabrics 22 are produced and accumulated un-der the beds. Each bed 13 has a set of hundreds of nee-dles 14. FIG. 8 shows the configuration of four needlebeds on a knitting machine. Four needle bed machines(such as the Shima Seiki Mach2X and the H. Stoll AG &Co. KG 730T, and 530T Electronic flat knitting machines)have two needle beds 13 with hundreds of needles 14,and additionally have auxiliary needle beds 15 with hun-dreds of fashioning points and/or needles 16, which cor-respond to the same spacing and occurrence of needlesin the beds below 13.[0010] In both four needle bed machines and two nee-dle beds machines, duration operation, strands of mate-rial 17 on cones or spools 18 are fed 19 into feeders 20.Several feeders are located on each machine and runalong rails 21 in a horizontal direction. The strands runthrough the feeders and are manipulated by the feedersboth feeders along the length of a pre-programmedlength of the needle bed 13 and in the horizontal weftdirection. At the same time, knitting needles 14 operateto interlace the strands into loops. The resulting fabric 22exits the machine under the needle beds.[0011] FIG. 10 shows a front view of an electronic knit-ting machine. An electronic knitting machine can be pro-

grammed and controlled to automatically select the nee-dles and other elements via mechanical and/or digitalinstruction process. (Cite: Knitting Technology, David JSpencer, Leicester Polytechnic, UK, Pergamon Press,1983, second edition 1989, third edition 2001; P43.)[0012] In shaping V-bed weft knitted fabric into a rein-forcing structure, such as that for a vehicle, there areseveral way currently utilized: cutting composite panelsand fabricate; flocking fiber into a mold; and applyingfiber mats or batting to a mold. For smaller components,precursor acrylonitrile fiber may be placed in a mold andheated several times, first at 400 degrees Celsius andthen again at 1300 degrees Celsius to remove the hy-drogen and line the carbon molecules in the hexagonalaromatic rings, which are more or less aligned parallelto the long axis of the fiber in a crystalline shape, makingthe fibers strong for their size. Scraps of this materialrarely can be used for other purposes and last an ex-tremely long time in a landfill due to the very reasons ofnear indestructibility for which this material is used.[0013] Seaming and sealing FRP materials are proneto human errors and fatigue in the seaming process.Seams create potential points of functional failure. In thecase of carbon fiber, fiber reinforcing materials, stainlesssteel, polyurethane coated, or other stiff reinforcing fib-ers, these potential problems are increased at the seam-ing points. Unlike common textile materials, introducingFRP materials, chain, wire, or other functional materialsto a standard OEM knitting machine causes several chal-lenges. Current methods of knitting carbon fiber and oth-er fiber reinforcing textiles, integrating stainless steel,wire, heating elements, chain, or other stiff fibers, posechallenges to the ’depackaging’ and feeding of those ma-terials into a conventional knitting machine utilizingstandard OEM stop motions and standard OEM feeders.FIG. 11 shows a right side view of standard stop motionson an OEM feeder. FIG. 12 shows a left side view ofstandard stop motion control on the OEM feeder. FIG.12 shows a bottom view of standard stop motions on theOEM feeder. The feeders are mounted on a stock OEMbar 23 above the needle beds, have built in manual ten-sioning controls 24.[0014] In FIG. 12, the stock OEM bar 23 has an elec-tronic cable 25 inside a groove, which connects eachstop motion to the machine’s main computer system. Stiffmaterial, such as carbon fiber, must bend several times26 through multiple right, obtuse, and acute angles (FIG.13), as it passes through these standard OEM fittings,and guides 27, causing a significant amount of friction,static build up that can damage machine computers andother machine electronics, breakage of fiber, excessivewear on the machine parts, drag of fiber slowing downproduction, and many other complications. Carbon fiber,wire, and many other functional strand materials are typ-ically packaged on a spool 18, a cylinder, or a cone 17device. When a material is deployed from the device, thematerial tends to balloon on itself and spiral into a coil.After several revolutions, the spiraling process can create

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a graduated spring in the fabric and in the slack strand,which is undesirable in and of itself. A strand twistingupon itself can cause fiber breakage, excess friction andabrasion on the machine parts that touch the fibers, andfinally breaking of the strand itself. Breakage can usuallynot be mended on the strand and/or the fabric growingin the machine, and results in waste scrap, productiondown time, damaged product, frequently damaged ma-chine parts needles, stop motions, knock over verges,sinkers, sinker, wires and other costly machine parts.[0015] Currently, the only practical alternative is usingone of the two products from a machine builder, depend-ing on which machine type the user is utilizing. Machinebuilders such as Shima Seiki of Japan, and H. Stoll AG& Co. KG of Reutlingen Germany have created unspool-ing devices to address such ’de-packaging’ or unspoolingof materials on spools, cones, and cylinders which posesuch problems. Both companies have large unspoolingdevices mounted on the floor or beside a machine, whichfeed up to two of these materials into a knitting machine.However, knitting a more complex structure, using morethan two unspooling strand feeds on standard machinebuilder equipment, such as fiber reinforcing structuresfor composites, such as vehicle panels, is currently notpossible.[0016] Polymer reinforcing fabric structure can be usedto create textures for different purposes including creat-ing added strength, non-skid surfaces and other types ofstructures requiring multiple strands of material. FIG. 14shows various textured knit structures that offer differentperformance characteristics. The textures may includehorizontal ribs 67, vertical ribs 68, vertical and horizontaltuck structures 69, creating a raised cardigan or half car-digan strength grid, bobble 70 non-skid raised nodes,three-dimensional raised spacer structures that have ahigher profile than the base fabric structure, short-rowedfabric 72, creating waves, which may include tunnels,channels or tubes which may be filled, empty or transportinternal materials such as wires, ceramics, or other ma-terials.[0017] Knitting complex structures requires transfersbetween the needle beds. Thus, an unspooling devicemay be required to unspool functional strands of carbonfiber, ceramic, alloys metal wires, and other fiber rein-forcing materials such as silicon, high heat resistant ce-ramics, vitreous silica fibers, thermo coupling wires,shape memory alloys Nitinol, metal components, braids,aramids, para aramids, fiber optic cable, and other spe-cialized materials which may be incorporated into the fib-er reinforcing structure in the same knitting process.Structures may be created with performance enhancingcharacteristics through knitting texture in specific place-ments. Examples are horizontal raised ribs 67, verticalribs 68, vertical and horizontal tuck stitches increasestitch density in a grid pattern, adding dimensionalstrength, bobble raised stites 70, raised geometric spacercorrugations 71, and short rowed fabric that creates di-mensional effects of waves, with raised tubular struc-

tures. The short rowing distorts the fabric grain and theraised tubes create a nonskid texture. One or a pluralityof unspooling devices may be mounted on one knittingmachine, FIG. 17, driving a plurality of functional strandsof carbon fiber, wire, or other special materials 28 off oneor a plurality of spools 18, cones 17, or other packages,in coordination with the movement of the knitting ma-chine’s feeder system 20. This feed system allows forintegrating of fiber, horizontally, vertically, and diagonallyby knitting, inlaying, floating, and tucking.[0018] The effect of fiber orientation on composite ma-terial properties is an important factor in the strategic de-sign of composite molding process. Mold cavity geometrycan vary greatly throughout the part, especially in vehiclepanels. Traditionally knits drape better than woven con-structions bi-directional. Knitting polymer reinforcing ma-terials to the dimensions of a mold shape cuts down onlay-up time, but also orients the fibers into tiny links, whichconform to the shape of the mold, much like chainmailconforms to a body. The resulting multi-dimensional fiberorientation has a direct correlation with mechanical prop-erties. Highly oriented fibers have a high modulus in thedirection of orientation and a much lower one about one-third as much in the cross-direction sides. Variation infiber alignment corresponds to variations in mechanicalproperties and tensile strength in even unsophisticatedpart geometry. Under mechanical loading, uni-directionaland bi-directional FRP carbon fiber sheets exhibit verystrong tensile strength. However, they can be brittle whentheir edges are impacted and typically exhibit a significantplasticity prior to rupture when bent. Knitted polymer re-inforcing fibers are multi-dimensional and can be knittedin a variety of thicknesses and constructions that limitstretch in the weft or warp direction. Simple construc-tions, such as ribs, can me added incrementally to im-prove strength.[0019] The density of current reinforcing fibers in acomposite structure may be seventy percent or more dueto the fact that the fibers themselves are responsible forthe mechanical properties of the resulting composite.Thermoplastic and/or thermoset matrix materials are typ-ically polyester epoxy, fluorocarbon, silicon, phenolic,etc. Ceramic composites are used in high temperatureand corrosive applications. Silicon carbide and othercompounds of silicon and aluminum retain strength upto 3000 degrees Fahrenheit.[0020] Matrixed composites can have various forms ofreinforcing material. For example, nonwoven mats, bat-ting, or chopped fibers are laid in place or fibers andflocked as a non-woven assembly of fiber material. Braid-ed tubes, braided webbing, warp knits, weft knits andwoven yarns "strands" used for reinforcing polymer ma-trices are typically homogenous, for example, the com-mon two-dimensional 2X2 twill pattern used for fabricat-ing carbon fiber panels. Woven fabrics interlace two ormore yarn systems, vertically and horizontally, creatingright angles or ’warp’ and ’weft’, and are the most com-mon reinforcement structure, utilizing glass, carbon,

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para-aramids, aramids and other materials.[0021] Woven panels, braded tubes, non-woven matsand knitted construction are typically regular in their for-mation and panel geometry, meaning they are rectangu-lar in dimension, typically roll goods, and ready for addi-tional cutting, forming, seaming and sealing processes.The mechanical properties of aligning fibers perpendic-ular to each other in a ’warp," and "weft" offers high den-sity of fiber, and modulus of strength, in relationship tofabric thickness.[0022] Carbon fiber matrix textile composites, includ-ing polyacrylonitrile fibers and other non-polymer fiberstrands as a precursor, which are carbonized, woven orlayered, and impregnated with resin, are two-dimension-al fiber reinforced polymer composite materials. The car-bon fibers are arranged perpendicular to each other in atwill weave. The most common weave configurations forcarbon fibers are: 232 Twill, 434 twill, five harness satin,plain weave and eight harness satin. Glass fibers aretypically non-woven to strengthen thermosetting resinconstructions which are commonly used in the aero-space, automotive, marine, and construction industries.FRPs are commonly found in ballistic armor as well.[0023] Matrixed composites can be laminated, mean-ing layers or plies of separate reinforcement materialsare stacked in a specific pattern, to obtain specific per-formance characteristics. The configuration of one layermay be different to the adjacent layer.[0024] Current woven fiber reinforced panel sheets arehomogenous in thickness and construction, having thesame properties throughout, with no ability to createbreathability, unless holes or perforations are cut into thesheet. Flexibility of the material is dependent on thick-ness and length and width of the cut piece. FPR sheetsrequire a lengthy process to create materials in sheetsto be used in fabrication. For example, carbon fiber canbe five times as strong as steel and twice as stiff as com-pared with the same unit of weight. Carbon fiber is mainlycomprised of carbon atoms that are bonded together andaligned to form the long axis of the fiber. Each fiber istypically five to ten microns in diameter and is made fromorganic polymers. Most carbon fibers are made from thepolyacrylonitrile PAN process, and others are made fromrayon or petroleum pitch process. Several thousand ofthese very small fibers are twisted together to form astrand. During the strand making process, the strand isoften impregnated with a resin. In the industry, this iscalled ’prepreg,’ as described above. Carbon fiber canbe woven into a twill fabric format from ’prepreg’, comin-gled, or unresinated stands. In the case of un-resonatedfibers, a mold is selected, and mold release applied. Thefabric is cut into the desired shapes then laid-up in thedesired geometric configuration of the mold and resin isapplied. A layer of plastic-coated absorbing material isapplied on top. The air is vacuumed out, pulling the resininto the carbon fabric, and then the assembly is left toharden. The absorbing fabric and plastic are removed,and the carbon reinforced polymer component, retaining

the shape of the mold is removed.[0025] Silicon carbide, vitreous silica, other com-pounds of silicon and aluminum, and carbon graphitearealso resistant to chemicals and tolerant to high temper-atures while exhibiting low thermal expansion. Becauseof its strength, corrosion resistance, lightness in weight,and flexibility, carbon fiber would seem a suitable mate-rial for shaped composite panels, and supportive com-ponents of vehicles. However current methods of utilizingcarbon fiber and additional fiber reinforced polymers instructured panels, such as those for vehicles, requiresourcing, purchasing, stocking, handling, cutting, bun-dling of both usable pieces and scrap, as well as special-ized care in disposal of a very durable scrap compositematerial, which will last indefinitely in a landfill. Recyclingcarbon fiber is expensive, requiring reheating of the ma-terials to melt the resin and repurpose the carbon. Typ-ically the fibers are short and chopped, and if repurposed,the resulting structures are not as strong using short fib-ers as they would be using the original filament material.Handling, cutting, and managing fiber reinforced polymermaterial sheets, including carbon fiber, requires specialsafety precautions, specialized cutting equipment. Fab-ricating partial components ready for molding or resinapplication to create composite panels, such as thosefor vehicles, requires many steps and processes.[0026] The advantages of knitted fiber reinforced fab-rications are the unique performance characteristics ofknits, whether warp knit, or weft knit structures, to drapeand conform to complex shapes in tools and/or molds.The structure of a flat V-bed knitted fabric can adapt tothe mold configurations, without puckering, bunching orgathering like woven fabrics, non-woven fabrics, andlamination structures. The disadvantage of conventionalroll good knitted reinforcement structures is that roll knitgoods that are currently used typically do not offer stiff-ness and/or alignment of fiber in any direction, horizon-tally, vertically, or diagonally.[0027] Stitching multiple types of composites togetheris typically done while fabrics are without resin impreg-nated or with materials in the pre-resin impregnated for-mat. The disadvantage is a high risk of damage to thefibers by sewing with an equally abrasive reinforcing fib-er.[0028] From the perspective of manufacturing, utilizingmultiple composite materials, which have different prop-erties and performance features, then cutting, seaming,and assembling those multiple materials into a vehiclepanel, can be a wasteful, labor intensive, and inefficientpractice. For example, the various materials utilized in aconventional vehicle panel may be obtained in differentwidths, lengths, thicknesses, densities, and packagingarrangement. The materials may be from a single sup-plier or many suppliers all over the world. Accordingly, amanufacturing facility must coordinate, inspect, invento-ry, and stock specific quantities of ready-made roll and/orpanel good materials with each material being a staticdesign created by raw material suppliers or in the case

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of fiber lay-up, the process may have different variationsdepending on the skill of the person doing the lay-up,fatigue, experience, and other human error. The variousraw good materials may also require additional machin-ery to prepare, inspect, or they may require sub-assem-bly line techniques to cut or otherwise prepare the ma-terial for incorporation into the vehicle panel. In addition,incorporating separate materials into a panel may involvea plurality of distinct manufacturing steps requiring sig-nificant labor, space, and resources. Additionally, in thecomposite manufacturing process it is generally desira-ble to minimize the number and types of materials in thepanel, particularly in three-dimensional fiber reinforcedvehicle panels. Fewer materials reduce costs due to extralay-up, layering, sub -assembly creation, risk of damagein each step prior to final lay-up, and increased efficiency,given that each component must be separately curated,coordinated, and prepared for an already labor-intensiveprocess.[0029] The typical fiber reinforced composite panelmanufacturing process encompasses the steps of se-lecting the material, cutting the base material compo-nents to shape, layering the thickness in strategic areasof abrasion and impact, joining edges, cutting holes, cre-ating three dimensional super-structures, laminating byadhesive or glue any added pieces forming the areas toattach hardware required by the design, shaping the pol-ymer reinforcing panel over and/or in a form and/or mold,heat-setting the materials and adhesives. Modern vehi-cle designs, principally organic and geometrically shapedfiber reinforced three-dimensional vehicle panels, re-quire numerous pieces and complicated manufacturingsteps, leading to high labor costs, lengthy time framesfor sourcing materials, fabrication compatibility issues,seam compatibility issues, production waste in the cuttingprocess. Combining separate materials into a cut andassembled type of complex composite panel involvesmultiple distinct manufacturing stages requiring multiplelabor actions and activities. Employing a plurality mate-rials and seaming techniques, bonding agents, in addi-tion to a plurality of shaping techniques, may for example,also make the composite panel heavier, and resulting inan overall vehicle that is less fuel efficient, less aerody-namic, less functional, and less aesthetically pleasing toboth the designer and the end user.[0030] Two specific categories of molding processesuse fibers: wet lay-up and dry lay-up. In wet lay-up, fibersare applied to a form and resin is poured and brushedinto the reinforcing fiber or textile. In dry lay-up, resinprepreg pre-impregnated fibers are used with resins al-ready absorbed in advance of placing into a mold. Drylayup employs high temperature and pressure to hardenthe pre-resinized fibers in the shape of the mold. Dry lay-up delivers better penetration of the resin and more uni-form resin thickness than the wet lay-up system.[0031] Conventional methods of manufacturing fiberreinforced polymer matrix panel structures, such as thoseused for vehicles, currently use labor intensive processes

to achieve three dimensional shapes with finished edges,seams, join points and closure points to achieve com-posites having high strength to weight properties and oth-er properties including high temperature resistant appli-cations. According to current manufacturing systems,those large two-dimensional fiber reinforced panels arecut and subjected to heat and pressure to form the three-dimensional shape. Aligning fibers in a multiplicity of spe-cific and measured directions on the X, Y, and Z planes,consistently and repeatedly, is challenging.[0032] Additionally, the current manufacturing proc-esses require handling and manipulation of loose fibers,cut or uncut rovings, and yarns which are flocked ontomolds, or laying woven fabric sheets, knitted fabricsheets, non-woven mats and/or bats into molds, or han-dling and cutting large cumbersome two-dimensionalcomposite panel, which are shaped, using specializedtooling for cutting and assembling processes.[0033] Current FRP composite panel components areformed by flocking a mold structure with cut fibers or lay-ering plies of woven mats, bats, or mono-tensioned knitmaterial of homogenous structure, applying resin andmolding, or cutting two-dimensional woven sheets of ho-mogenous fiber reinforced materials, molding the cutparts to one or more curves, and seaming the elements,where each seam represents a join. Each facet and/orplane is created by bending cut and joined pieces of thetwo-dimensional FPR composite sheets around thecurves of a vehicle. If the vehicle is small and has tightcurves, such as a drone, boat, or smart car, utilizing wo-ven two-dimensional sheets of homogenous fiber rein-forced materials poses several challenges. First, wovenFPR materials align fibers in two directions, warp andweft horizontal and vertical. To achieve more than twodimensions the FRP sheet needs to be bent moldedand/or other material needs to be stacked and/or applied.Second, cutting, dynamic tensioning of bending cut piec-es, and joining edges of cut pieces, takes considerableequipment and effort. Creating the desired FRP shapemay take several after processes to structure the two-dimensional FRP parts. Additionally, finished two-dimen-sional FRP panel sheets made with epoxy resin cannotbe bent to hold a curved shape, due to the panels notbeing heat formable thermoplastic. A limited amount ofcurvature can be permanently applied to a carbon fiberreinforced polymerized panel sheet "graphene rein-forced polymer" and in one direction, using high heat overtwo-hundred degrees Celsius. Simple curves, such as acylinder shape, can be applied to a carbon Fiber Rein-forced Polymer panel sheet of carbon fiber. However,applying a panel sheet of carbon Fiber Reinforced Poly-mer to a complex curve such as a sphere, as would beneeded in a pod shaped design is not possible. Fiberreinforced panels must be cut and pieced together to fitshapes. Currently, there are several methods to cut FRPsheets, ready for shaping. Cutting polymerized compos-ite sheets presents special handling and safety concernsdue to the cutting process expelling loose fibers into the

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environment. Although most fiber reinforcing materialsare not toxic, loose fibers are an irritant to skin, lungs,and eyes. Cut edges may be very sharp, and have splin-ters, creating additional handling concerns of sheet pan-els and cut pieces. In cutting carbon FRP panel sheetswith a CNC machine, highly experienced skills are re-quired. Yet, it is difficult to hold the sheets in the machine,which results in handling issues described above, poten-tial damage to the FRP sheets themselves, and a highpotential for defect rates in cut parts. Die cutting carbonFRP sheets also requires highly-skilled experienced op-erators. Water-jet equipment for cutting carbon FRPsheets also requires, expensive complex machinery andhighly-skilled experienced operators. Specialized adhe-sives are required to seam FRP panel pieces includingcarbon fiber cut pieces. The seaming process adds sig-nificant time and effort due to time required for adhesivesto dry thoroughly. Moisture from adhesives react with pol-ymer resin, causing the fiber reinforced part to bubbleover time and/or the seam to fail.[0034] Third, joining two-dimensional planes may re-sult in potential fail points. Seams in common materialscreate potential failure points. Besides requiring special-ized materials, special adhesives, extra time, and oper-ator skills, seaming stiff materials such as composites,which want to revert back to their sheet form, are difficultto work with, handle, cut, and seam. Problems with seam-ing may not arise for some time after the fiber reinforcedcut parts are already functional in an assembly. Fourth,joins in two-dimensional FRP sheets create potentialthick or thin spots in the reinforcement as well as creatingpotential aesthetic defects and potential failure spots inthe part. Fifth, the cutting and fabricating the two-dimen-sional FRP material itself, creates significant waste ofnearly indestructible material, which may not be able tobe recycled. Sixth, additional materials or strengtheningparts need to be applied in separate processes takingadditional assembly time and equipment. Any additionalstructure elements or reinforcement elements layeredonto the woven panel require one or more sub-assemblyprocesses, prior to the final forming process. The partsapplied may present added potential failure points. Aes-thetically, the additional may not lend themselves to astreamlined and aerodynamic look and appear clunky.Flocking a mold structure with cut fibers may create asmooth structure, but the panel strength requires but-tressing and or additional structures to be applied for add-ing strength to large areas. The orientation of the fiber issubject to individual users’ skills, and each sequentialunit is also subject to individual users’ skills, fatigues,environment and ability to duplicate repetitive processesaccurately. Similarly, layering plies of woven mats, bats,or mono-tensioned homogenous knit material structureis also subject to individual users’ skills, fatigues, envi-ronment and ability to duplicate repetitive processes ac-curately, applying resin and molding. Rudimentary three-dimensional knits used in reinforcing current compositesprovide better drape to fit the shape of a mold, but are

typically knit as individual sub assembly components,which are later assembled. Similarly to flocked cut fibers,large areas of three-dimensional fiber reinforcing knitsrequire buttressing and or additional separately knittedstructures to be applied for adding strength to large areas.

BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The embodiments can be better understoodwith reference to the following drawings and description.The components in the figures are not necessarily toscale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the fig-ures, like reference numerals designate correspondingparts throughout the different views.

FIG. 1 illustrates the composition of a composite ma-terial.FIG. 2 shows different reinforcement fiber orienta-tions in composite materials.FIG. 3 illustrates a knit-reinforced composite.FIG. 4 shows common carbon fiber weaves resultingfrom a knitting process.FIG. 5 shows the loops and stitches formed in a weftknitting process.FIG. 6 shows the needle beds and needles in a knit-ting machine.FIG. 7 shows the configuration of two needle bedson a knitting machine.FIG. 8 shows the configuration of four needle bedson a knitting machine.FIG. 9 shows the configuration of a knitting machinewith strand feeding.FIG. 10 shows a front view of an electronic knittingmachine.FIG. 11 shows a right side view of standard stopmotions on an OEM feeder.FIG. 12 shows a left side view of standard stop mo-tion control on the OEM feeder.FIG. 13 shows a bottom view of standard stop mo-tions on the OEM feeder.FIG. 14 shows various textured knit structures thatoffer different performance characteristics.FIG. 15 shows an exemplary intarsia structure gen-erated in a knitting process in accordance with anembodiment of the present disclosure.FIG. 16 shows an exemplary warp insert and spacerstructure generated in a knitting process in accord-ance with an embodiment of the present disclosure.FIG. 17 shows the arrangement of multiple spool de-vices on an exemplary knitting machine in accord-ance with an embodiment of the present disclosure.FIG. 18 shows exemplary multi-functional knittedstructures in a vehicle panel construction in accord-ance with an embodiment of the present disclosure.FIG. 19 shows wedge structures knitted from poly-mer reinforcing fibers for use on a motorcycle ac-cording to an embodiment of the present disclosure.

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FIG. 20 shows exemplary aircraft panel with voids,vertical inlay and warp inlay, that are generated in aknitting process according to an embodiment of thepresent disclosure.FIG. 21 shows short row narrowing inside miter re-sulting from a knitting process in accordance with anembodiment of the present disclosure.FIG. 22 shows the short row additive miter in a knit-ting process in accordance with an embodiment ofthe present disclosure.FIG. 23 illustrates the knitting stitch paths of an ex-emplary insert structure to a panel construction sin-gle or double bed structure in accordance with anembodiment of the present disclosure.FIG. 24 shows an exemplary knitted FRP vehiclepanel with appendages, void and miter of corruga-tions (double bed fabrics) that is produced from aknitting process in accordance with an embodimentof the present disclosure.FIG. 25 shows the configuration of an exemplary au-tarkic feeder in accordance with an embodiment ofthe present disclosure.FIG. 26 shows an overlapped panel join and splineedge that are created in exemplary knitting processin accordance with an embodiment of the presentdisclosure.FIG. 27 shows exemplary three-dimensionallyshaped jacquard panels using two colors of polymerreinforcing fiber that are generated in a knitting proc-ess in accordance with an embodiment of thepresent disclosure.FIG. 28 illustrates various exemplary panels usedon aircraft that have carbon fiber structures manu-factured through an exemplary knitting process inaccordance with an embodiment of the present dis-closure.FIG. 29 shows fiber reinforced panels in a marineapplication produced in a knitting process in accord-ance with an embodiment of the present disclosure.

SUMMARY OF THE INVENTION

[0036] Embodiments of the present disclosure providea mechanism of knitting a polymer reinforcing structureto a shape as predefine in the final product, which allowseasily integrating specific materials into particular areas,enables transition or blend the reinforcement, conductiveproperties, or other specific performance features, intoregions for enhanced specific function performance aswell as manufacturing efficiency. For example, an exem-plary knitted polymer reinforcing structure is capable ofreinforcing against ballistics or other forms of damage;providing seamless flex; creating areas of corrosion re-sistance and/or other performance features; better se-curing the panels to a chassis; creating cavities for inser-tion of after-process hardware; embedding heat shieldedwiring in the knit process; creating attached dimensionalreinforcing structures in areas; minimizing waste of ma-

terials; better managing production materials and supplychain; streamlining mass-production process; reducingcosts; allowing for simplified mass-customized produc-tion structures, and ease of implementing manufacturingapplications.[0037] Embodiments of the present disclosure allowfor one or more knitted components to be formed exclu-sively in a knitting process and applied to a panel lay-up,ready for a molding or resin application process. Creatingthree-dimensional interlocking and multilayered reinforc-ing fabrications, which are knitted or woven, advanta-geously create stronger matrixed composites than lam-inated composites in relationship to thickness of thestructure.[0038] Embodiments of the present disclosure utilizefiber reinforcing polymer (FPR) matrices to build threedimensionally knitted-to-shape polymer reinforcing pan-els and panel components, with dimensional reinforcingstructures knitted mathematically and proportionally ar-ranged and/or reinforcement materials mathematicallyand proportionally arranged in a unitary construction. Aresultant panel or panel component provides strength,cross structured performance characteristics, and canbe made lightweight, which is critical to smart vehicles,aerospace transportation, electric vehicles, and othermodes of vehicle transportation.[0039] An exemplary knitting process can generate acomposite polymer matrix component panel in the formof a unitary construction of a three-dimensionally weftknitted polymer reinforcing fiber structure. In some em-bodiments, in the knitting process, one or more stiff ma-terials are drawn into a V-bed weft knitting machine tocreate a polymer reinforcing panel structure and any ad-ditional knitted textile elements with completely finishedthe edges. The knitting process is performed exclusivelyon knitting machine, with nearly zero scrap waste of thestrands used to fabricate knitted fabrics.[0040] In the same unitary panel construction, the knit-ting machine may create thick and thin zones, dimen-sional structures, such as pockets, tunnels, channels,voids, cavities, warp structures, corrugations, spacers,additional layers, portions of layers and appendage ele-ments as functionally required as well as aestheticallydesired elements such as jacquard designs, three dimen-sional textures, surface interest stitch design patterning,and etc. The knitting machine can incorporate functionalstrands in the same knitting process to strategically en-hance the performance and/or characteristics of the fiberreinforced polymerized composite material. For exam-ple, the functional strands can be silicon, high heat re-sistant ceramics, vitreous silica, thermo coupling wires,braids, aramids, para aramids, chain, basalt, insulatedfiber optics, insulated wire, silicon rubber, sacrificial ma-terials which dissolve in the forming process, insulatedauxetic materials, micro-fibers, nano-fibers, synthetic,and other traditional fibers for aesthetic or performancefeatures. Dependent upon specific performance needsof the resultant composite structure, strengthening, heat

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dissipating, and vibration dampening, materials may bemathematically arranged for specific functions in threedimensions proportionate to the length, width, and di-mensional cross sections, spanning the unitary construc-tion of layers and layer components in multiple directions.That is, the resultant composite structure is mathemati-cally and proportionally shaped.[0041] The resulting combination of three-dimensionaltextile elements is a unitary construction completed en-tirely by the knitting machine in the knitting process, andis ready for a subsequent polymer resin applicationand/or a molding process. Knitting fiber reinforcing ma-terials to one or more desired shapes greatly simplifiesthe final structuring, alignment, and lay up process,where resin is added to the material in a mold, or in thecase of resin pre-impregnated materials, one or moreembedded heat resistant strengthening and or vibrationdampening materials may be knitted into the textile com-ponents, and the entire assembly may be molded in anoven or autoclave. The shape of a knit reinforcing struc-ture may be defined by the product design of a panel, apanel portion, a panel component, and/or attached com-ponent, etc. The added strategic performance and/orcharacteristic enhancing materials can survive the resinpolymerization process and/or molding process and arethereby permanently embedded in the panel, panel liner,and/or components.[0042] In some embodiments, a dynamic feeding sys-tem is used for a knitting machine to introduce a varietyof polymer reinforcing materials, conductive materials,and other functional materials in creating the unitary con-struction.[0043] In some embodiments, a polymer reinforcingfiber structure for a panel structure and/or componentscan be produced by a knitting process, including a unitaryconstruction, in which a single or multi-layered fully-shaped three-dimensional polymer reinforcing fiberstructures for a composite panel, such as a panel utilizedin vehicle assembly, liner, and/or component are knittedand attached in the same knitting process. The polymerreinforcing fiber structure is knitted and finished on a V-bed flat knitting machine to the predefined shape withone or more layers, each having one or multiple perform-ance zones, each zone made up of one or more, two-dimensional or three-dimensional stitch structures thatare mathematically arranged in proportion to the size,shape, configuration, and performance nature of the lay-er or layer portion in the composite structure, and thecombined performance needs of the resultant compositepanel. Each layer may also include additional materialsor structures arranged in a manner to provide desiredfunctional or aesthetic attributes. The total layers, por-tions, and appendages when plied, gathered, and or fold-ed together create the three-dimensional panel ready formatrix application or in the case of resin pre-impregnatedmaterial, the molding process. The polymer reinforcingfiber structure may include a fully shaped integrated knit-ted insert with a grain in a steep right or obtuse angle.

The insert is shaped, configured and manipulated intoplace exclusively by the knitting machine, requiring noseaming or joining to attach the insert to the main bodystructure. Utilizing a knitting machine to automaticallyclose or seal the edges, and to incorporate a functionaldesign or pattern lines, or other specific performance fea-tures, creates a unitary construction with no seams andnearly zero waste.[0044] According to embodiments of the present dis-closure, a composite structure having a polymer matrixmaterial is produced through a knitting process, which isreinforced by fiber construction. In some embodiments,a three-dimensional V-bed knitting process creates mul-tiple structures in the same panel structure and utilizevarious materials strategically, and or mathematicallyand proportionally, placed for specific characteristics toimprove the composite panel manufacturing process andor function of the resultant panel, such as materials stra-tegically and mathematically placed proportionallyplaced by the knitting machine to add strength to specificareas, temporary supporting sacrificial material that dis-appears in the molding process, material that creates flexjoins or live hinges in the knit structure, material that ex-pands to support structures with the addition of heat andor steam, shape memory material, vibration dampeningmaterial; materials that create voids or cavities of shape,dimension, and positioning in the resultant compositestructure; materials strategically placed to shield RF orEF; heat resistant electronic cables and or thermo cou-pling wires that permanently situate connection spots inthe resultant composite panel ready for after processhard ware components such as electronics, solar ele-ments, power sources, navigation, lidar, radar, cameras,controls, acoustic amplifiers, screens, monitors, or otherdevices. According to embodiments of the present dis-closure, the knitting machine may utilize a knit programto incorporate one or more pocket structure knit into oneor more layers, where a component is inserted betweenthe needle beds of the knitting machine and into the pock-et during the knitting process, manually or robotically, theknitting machine then continuing and sealing the compo-nent into the knit structure. The component may be anycomponent, for example an electronic component, anRFID sensor, a ballistic plate, a foam, computer chip, aprinted circuit board, a battery, or other component. Thepocket may be completely closed of have an opening,void, flap, or other structure allowing access to the em-bedded component.[0045] The knitting process can be controlled by a com-puter program to render specific structures of differingconstructions, varying thicknesses, aesthetic or function-al openings, functional structures (such as pockets, tun-nels, channels, corrugations), spacers, tubes, flaps,voids, and dimensional reinforcing structures. Append-ages, sub-structures, super-structures, liners, and em-bedded wiring, additional reinforcement, and/or ballisticmaterials, may also be knitted, inlaid, inserted, or weftknit warp inserted in the same knitting process. Append-

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age, liner, portions of layers, inserts, and/or reinforce-ment structured fabric may be gathered, aligned, pliedfolded over, and pressed together lining up calculatedzones to constitute a strategically shaped and plied groupof layers or zones to create the polymer reinforcing three-dimensional panel structure or one or more appendagestructures, liner, portions of layers, inserts, and/or rein-forcement structured fabric may be separated into small-er panels by knitting in different strands connecting suc-cessive layers of the polymer reinforcing panel in a se-quential manner.[0046] An exemplary three-dimensional polymer rein-forcing structure may be used in vehicle assembly andmay be generated by utilizing a V-bed knitting machine.The knitting process advantageously reduces labor costsby shaping the reinforcing fiber in the knitting process;minimizes the number of manufacturing steps in com-posite formation; minimizes wasted materials from cut-ting, stacking, assembly and sub-assembly processes;minimizes the number of manufacturing steps from a two-dimensional composite panel; minimizes the number ofmanufacturing steps in a three-dimensionally knittedcomposite textile panel, which would otherwise requiresub-assemblies, multiple different structures, and seamson various positions on the panel; minimizes the materi-als handling equipment and floor space required to re-ceive and process fiber reinforced polymer panels. In thismanufacturing process only raw material spools arestocked and subsequently processed by the knitting ma-chine. The resulting fiber reinforced polymer panelsand/or panel components have completely finished edg-es and enter the composite matrixing or heat finishingprocess as a unitary construction.[0047] In some embodiments, a polymer compositepanel made from a fiber reinforcing structure includes asingle piece three-dimensionally-shaped liner panelstructure. A single or multi-layered three-dimensional fib-er reinforcing structures are knitted to shape with multipleperformance zones, and/or including an aesthetic and/orfunctional fabric face, finished edges, apertures, varyingthickness, embedded wiring, embedded sensor, embed-ded solar cells, embedded ballistic inserts, and/or func-tional structures such as electronic housing voids, chan-nels, tunnels, pockets, device housing cavities. The knit-ting process may combine one or a plurality of integratedmaterials mathematically and proportionally arranged inaddition to the base fiber reinforcement material. A knit-ting machine is utilized to automatically close or seal theedges and incorporate a functional design, aesthetic jac-quards, surface design, embedded technology, or aes-thetic pattern lines, or other specific performance fea-tures, including creating cavities for insertion of after-process hardware; embedding heat shielded wiring inthe knit process; creating attached dimensional reinforc-ing structures mathematically and proportionally ar-ranged throughout the various panel components, there-by creating a unitary construction. The automated proc-esses are advantageously consistent and repeatable in

production, and lead to nearly zero waste in the lay-upand polymerization process.[0048] Embodiments of the present disclosure enablecreation of a three-dimensionally shaped polymer rein-forcing fiber structured panels to be mathematically andproportionally shaped and formed in the fiber reinforcingtextile material on a V-bed flat knitting machine, such asthose for vehicles, and/or one or more panel liners, and/orone or more inserts, and/or one or more semi-finishedcomponents. A panel liner and/or components may beknitted to predefined shapes in a separate process andthen attached to the body of the main panel in an afterprocess. Alternatively, or the panel liner and/or compo-nents may be knitted and attached to the body of themain panel in the same knitting process. In the latter man-ner, the body of the panel structure or a panel liner or aninsert, has no extra seams, seal points or closure points,and is knitted exclusively utilizing the knitting machinewithout requiring human intervention. The knitting proc-ess creates a seamless, three-dimensionally shapedstructured panel, such as those for vehicles, as a unitarytextile construction, with one or more integrated compo-nents. An entire structured panel can be completed ex-clusively by the knitting machine, ready for the polymer-ization resin application, or in the instance of resin pre-impregnated stands, the molding process, and then thepanel assembly process.[0049] An exemplary knitting process can result in astrong amorphous oriented textile structure, where fibersare knitted into a three-dimensional shape and the knitmay be varied and structured into zones for the desiredend use. The resulting textile construction is further proc-essed with the addition of polymer into an FRP compositeand may be co-molded with other materials to createfunctional zones and/or processed as a fiber, which ispre-impregnated with resin pre-preg and molded intoshape with heat and pressure.[0050] The fiber structure may be curved multi-direc-tionally in the knitting process into a void to receive, sup-port, and/or link with other hardware to hold the panelsin place. Varying the fibers mathematically and propor-tionally in zones to map desired functions may create aflexible, dynamically structured, and multi-functionalcomposite panel, which may also be very light weight ascompared to the current process of fabricating homoge-nous two-dimensional sheets of composite material,flocked cut fiber lay-up, bat lay-up, or current rudimentarythree-dimensional knits used in reinforcing current com-posites. Knitting polymer reinforcing fibers to shape pro-vides several advantages. Exceptionally strong rein-forcement can be achieved by creating small arches, inwhat the trade calls an "amorphous orientation" whichspread the reinforcement in multiple directions simulta-neously. Rather than just two directions, warp and weftas in woven FRP sheets, knitting aligns fibers into: loopstructures, V-tuck structures, corrugations, corners, box-es, tunnels, channels, ellipses, and other three-dimen-sional aesthetic and/or functional configurations, includ-

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ing complete panel shaped configurations. Further, thesame strands of material run through the panel, liner orcomponent appendages, bending in multiple directions.Knitting fibers for reinforcing a polymer to shape on a V-bed knitting machine eliminates the need for cutting andrequires only the knitting machine to create the dimen-sionally shaped polymer reinforcing fiber structure. Fur-thermore, fibers for reinforcing a polymer are knittedmathematically and proportionally to a more aerodynam-ic, anatomical, complex curved shape or to the shape ofthe mold and also reinforced dimensionally and or cohe-sively in a mathematical and proportional manner. Thiseliminates or minimizes the need for joins, mitigates un-desirable flat sections, and naturally drapes to hardcurves in shaping as compared to two-dimensionalsheets, flocked cut fiber lay-up, bat lay-up, or current ru-dimentary three-dimensional knits used in reinforcingcurrent composites.. There is no need for short term orlong-term monitoring of seams as knitting to shape elim-inates most need for piecing and thus eliminates thoseseams. Still further, knitting fiber reinforcing material todesired shape and structure uses only what is neededto create the part. The edges are completely finished,requiring no cutting. Still furthermore, adding additionalfunctional materials to a polymer reinforcing fiber in theknitting process embeds the materials in the structure atthe same time and in the same process. Additional as-sembly equipment, creating sub-assemblies, bundling,and coordinating for assembly may not be necessary tocreate the reinforcing structure complete with the em-bedded additional materials, thereby eliminating addi-tional processes, joins, and potential failure points. Aes-thetically, the additional materials may be placed on thesurface, on the interior, or internally inside the main bodystructure in the same knitting process.[0051] A knitting process according to embodimentsof the present disclosure can eliminate the need for mostseaming in both the textile creation process and the po-lymerization process by creating a multi-structured fiberconfiguration in a true unitary textile construction, shapedentirely by the knitting machine, ready for the polymeri-zation process. It also eliminates waste in both the textilecreation process and the polymerization process by cre-ating a stable finished panel in a true unitary seamlesstextile construction shaped entirely by the knitting ma-chine, ready for the polymerization or molding process,and requiring no cutting and joining of composite com-ponents.

DESCRIPTION OF THE INVENTION:

[0052] According to embodiments of the present dis-closure, polymer reinforcing textile fabric structure to sup-port a panel, such as that utilized in vehicle, may be cre-ated on a V-bed knitting machine as single bed "jersey,"double bed fabric, spacer fabric, pointelle, intarsia, netfabric, multi-dimensional structure, attached insert struc-ture, weft knit warp structure, or other knitted construction

or combination of knitted structures. Besides fiber rein-forced polymers (FPRs), additional aesthetic or function-al material strands can be combined with the fiber rein-forced polymer material, such as natural fibers, metalizedfibers, wire, filaments, chain, silicon, vitreous silica, ce-ramic, elasticated, synthetic and other traditional fibers.Multiple FPR materials may be used in the knitting proc-ess. including hemp, flax, linen, glass, basalt, carbon fib-er "graphene reinforced polymer", nano-composites, na-no materials, optical fibers, FR materials, biodegradableaccelerants, and others, which may be polymer extru-sions, pre-matrixed yarn constructions, filaments, copol-ymers, bi-components, or other strand compositions orcombinations. These materials can be fed into the knittingmachinery to create three dimensional composite ma-trixed polymer reinforcing panels and can be knitted orinlaid into the shape, e.g., a shape predefined as in afinal product.[0053] In some embodiments, a three dimensional fullyshaped polymer reinforcing panels may be knitted fromresin impregnated pre-carbonized strands. A binderstrand may also be twisted with the carbon fiber. A knittingprocess results in a three dimensionally shaped polymerreinforcing fiber composite matrix panel, ready for bothdry lay-up heat processing, and wet processing resin ap-plication. The knitted panel having no seams, join points,closure points, or human intervention. In some embodi-ments, the polymer reinforcing fiber panels may be knit-ted from oxidized acrylic strands and then heated to car-bonize the strands, and a resin injected in a separateprocess. In some embodiments, the three-dimensionallyknitted carbon fiber fabric panels may be embedded ina carbon template with additional carbon vapor deposi-tion to form the shaped polymer reinforcing panel andthen heated to carbonize the yarn.[0054] Knitting on flat bed weft machines offers oppor-tunities that are not possible in weaving, including com-pound curves and knitting to shape on a knitting machine,which is currently available up to ninety-six inches wide.The V-bed three-dimensional knitting process may cre-ate multiple structures in the same panel, digitally pro-gramming specific structures of differing construction,varying thickness or open spaces, and varying stitch den-sity where required in a straight grain, turned cloth, bias,or multi-directional manner.. FIG. 18 shows exemplarymulti-functional knitted structures in a vehicle panel con-struction in accordance with an embodiment of thepresent disclosure. In some embodiments, openings,pockets, appendages, ventilation, live-hinges, wasteseparation 46, sub-structures, super structures, and lin-ers 47 may be knitted in the same knitting process.[0055] One or more appendages, liners, or reinforce-ment structured fabric layers may be aligned and pressedtogether into zones to constitute a strategically pliedgroup of layers 48 or zones to create the strategicallyshaped three-dimensionally panels. Such panels can beused for vehicles can may be separated into smaller in-dividual components by knitting in separating strands and

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connecting successive layers of the three dimensionallyshaped unitary panel structure 61. Voids (51 in FIG. 20),such as complex window element or hardware elements,may also be created through the knitting process andmay utilize sacrificial yarns. FIG. 19 shows dimensionallyreinforced wedge structures knitted from polymer rein-forcing fibers for use on a motorcycle front panel accord-ing to an embodiment of the present disclosure.FIG. 20shows exemplary aircraft panel with voids, vertical inlayand warp inlay, that are generated in a knitting processaccording to an embodiment of the present disclosure.[0056] Finished edges can be knitted around one ormore open areas of varying shape. Also can be madeinclude aesthetic or functional structures such as pock-ets, tunnels 50, and channels. The components may beknitted and inserted with hardware, electronics, ballisticpanels, or other functional components. Complex curvesmay be knitted to fit the mold. Spacers may add strategiccorrugation 49 to one or more areas of a curved structure,integrating a stiffened axial load. Jacquards may be knit-ted in fiber types or colors to add aesthetic design. Theliner may be attached to the unitary construction by a livehinge 46. An important benefit is that fibers may be knittedto required dynamic performance structures and theshape of the mold in three-dimensions (FIG. 19), savingcutting, minimizing lay-up time, and eliminating wastage.Curves, wedges 52, and/organic shapes, attached di-mensional reinforcing structures, cavities for insertion ofafter-process hardware, may be knitted using the afore-mentioned short rowing technique 53.[0057] In some embodiments, a four-needle bed ma-chine is used which allows creation of an insert 54, e.g.,up to seventy-two inches wide. The grain of the fabricusing the insert technique as previously described, turnsninety degrees in the finished polymer reinforcing struc-ture. This fiber alignment may lend strategic strength, asthe shape is created planar, convex, or concaved com-pletely by the knitting machine. Inserting a panel in thismanner is not limited to one stitch wide, by one stitchhigh shaping, provided by standard fully fashioning. FIG.19 shows a sequence of two-dimensional and three-di-mensional structures, which are knitting in sequence bythe machine from the bottom upward. The top structure,an insert 54, is then transferred to the unitary structureand becomes the top most part of a three-dimensionalstructure fitting the mold, for in this instance the front partof an intricate motorcycle.[0058] Materials may also be knitted into componentswith specific performance characteristics, such as Kev-lar, heat shielded wiring, heating elements, shielded de-vice wiring harnesses, shielded thermo coupling wire har-nesses vibration dampening material, heat dissipativematerial,. These components may be incorporated in thesame knitting process to provide function. The knittingprocess may also create sacrificial materials 55 whichdisintegrate, evaporate, detach or melt in the moldingprocess. Materials may be knitted in specific areas toresist resin, such as Teflon and other types of fiber. In

using resin pre-impregnated fibers, heat resistant mate-rials, such as silicon, may be knitted in intarsia areas toisolated areas of rigidity with areas of ligamental stretch.The heat resistant material is unaffected by the moldingprocess or in the case of un-impregnated or comingledmaterials, the oven or autoclave. Support fibers may beknitted, which expand when exposed to heat or steam,creating dimension, acoustic insulation, further reinforce-ment, and or increased stitch density. Density of fibersmay be manipulated by the machine into zones, createdin a gradient, latticed, layered, weft knit warp insertion orany combination of knit structures. The computer-con-trolled knitting machine consistently and repeatedly man-ufactures the same fiber reinforcing parts for as manyand as few as desired.[0059] Fully fashioning polymer reinforcing fiber struc-tured panels saves considerable material, which wouldotherwise be cut away in a cut and sew process, or cutand discarded after polymerization. In fashioning poly-mer reinforcing fiber structured panels on a two-needlebed flat knitting machine (e.g., as shown in FIG. 11), atypical wedge knitting short rowing technique can beused to turn the grain of a structure miter of two pieceswith a void in between. The result is a miter on each. FIG.21 shows short row narrowing inside miter resulting froma knitting process in accordance with an embodiment ofthe present disclosure. The machine transfers one nee-dle on each row at a time as each row is sequentiallyknitted, while holding the stitch on the horizontal row 29.By the time the machine gets to the final stitch to be trans-ferred, the final loop has tremendous tension on it.[0060] Similarly, shaping the sides of a fabric, usingshort rowing to create miters on both sides creates shap-ing simultaneously, However, the fabric shaping on two-needle bed machines, of current rudimentary three-di-mensional knits used in reinforcing composites, usingshort row wedge knitting, has the limitations of increasingor decreasing by one-needle wide, by one-needle highat a time, creating an acute angle, which is subject tovariations in materials. Short-rowing cannot make a rightangle. Increasing or decreasing by more than one needlewide by one needle high creates stress on the knittingstrand and the knitting needles in pulling a long loop 29,which spans a space two or more times longer and wider,than the original loop. This results in a fail in knittingand/or a high stress fault line in the fabric that may notendure abrasion, tensile stretch and recovery. Carbonfiber and other fiber reinforcing materials are inherentlystiff. Stretching loops of fiber reinforcing material fartherthan one stitch width at a time may actually cause seriousdamage to the knitting needles and other parts of theknitting machine. Utilizing this short rowing wedge knit-ting technique one stitch width and one stitch height at atime creates a polymer reinforcing fiber structured panel,which may require one or more seams to miter and jointhe sides, completing the polymer reinforcing fiber struc-tured panel’s shape, if the sides are greater than allow-able for fashioning. Shaping, using this wedge knitting

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short row technique, typically limits the angle of the grainchange in current rudimentary three-dimensional knitsused in reinforcing composites, to between thirty-five andseventy degrees, depending upon the material qualities,the angle of the main body grain. Adjacent areas of apolymer reinforcing fiber structured panel in current ru-dimentary three-dimensional knits used in reinforcingcomposites are limited by the mechanical transferringconstraints of two-bed flat-knitting machinery, and alsothe structure of stiff fibers, and knitted double-bed fabricsin general. Utilizing this wedge knitting technique shortrowing, in current rudimentary three-dimensional knitsused in reinforcing composites, there is no transferringof double-bed fabric loops, only adding of new rows ofloops in a wedge like shape short rowing, which is astandard and historically used weft-knitting technique.Short rowing distorts the fabric grain on an angle. In-creasing or decreasing the degree of the short row angleis limited by one-needle in the X direction by one-needlein the Y direction, as described above. Moving more thanthis one-needle wide by one-needle high stretches loopsand creates potential failure points as also described. Inutilizing stiff polymer reinforcing fibers, wires, Kevlar orother aesthetic or functional material strands describedherein, there is already limited to no stretch available.[0061] In some embodiments, an insert is knitted inone or more section, adjacent to a side of a portion ofknitting to which it is to be attached, and is manipulatedby the machine into place in the same knitting process.The loops of the insert travel a very short distance toconnect to the side of a portion of knitting. FIG. 23 illus-trates the knitting stitch paths of an exemplary insertstructure to a panel construction single or double bedstructure in accordance with an embodiment of thepresent disclosure. The polymer reinforcing fiber struc-tured panel’s fabric grain may change direction ninetydegrees or more in the knitting process as the insert isformed. Consequently the stitches appear perpendicularto the main body panel’s fabric grain. During this processof creating and insert or other attachment, the doublebed loops of the opposing side of the insert are trans-ferred to the additional third and fourth needle bed andthen attached to the main body fabric as the shape re-quires. All movements are performed exclusively by theknitting machine, with no human intervention. Additionalnon-polymer reinforcing material strands may be com-bined and comingled with the fiber reinforcing materialstrands, to obtain additional desired functional charac-teristics, such as silicon rubber, wires, braids, thermocoupling wires, vitreous silica fibers, silicon, ceramics,basalt, para aramids, insulated fiber optics, insulatedwire, aramid fibers, chain, silicon rubber, sacrificial ma-terials which dissolve in the forming process, syntheticand other traditional fibers for aesthetic or performancefeatures. A plurality stitch structures may be knitted intospecific areas mathematically and proportionally ar-ranged as needed for the functional performance char-acteristics required of the particular zone and the overall

panel. For example, flat areas may be more densely knit-ted; a portion may incorporate a net or open structure forventilation; a portion may incorporate three-dimensionalreinforcing structure. Appendages may include aestheticelements or insulated electronic elements, which maysurvive the polymerization temperature and process,such as Pelican wire of Florida’s 300 C rated wire or othersimilarly insulated electronic material and/or device.Spacer fabrics, when filled with resin, provide an ex-tremely rigid construction that resembles a corrugation.Corrugated structures 45 may be desired in extreme en-vironments that require strict rigidity and protection. Cor-rugation may be graduated in thickness, and dimension-ally shaped, and or created in one or more isolated areasas an intarsia structue, on a V-bed knitting machine,which is not possible in warp knit fabrics. In some em-bodiments, utilizing this inventive process, additional re-inforcing materials or more complex double bed struc-tures may be knitted, inlaid or ’warped’ into the knittedstructure to impart even stronger areas of rigidity, con-ductive materials, interactive materials, or other charac-teristics to one or more zones of the panel.[0062] An example of adding rigidity is adding spreadtow fabric STF materials. STF may be inlaid in the knitstructure, reinforcing one or more zones horizontally orvertically as a weft knit warp structure with carbon fiber’tapes.’ Instead of ’bundling’ the carbon fibers in narrowand thick tows or slivers, spreading fiber in thin and widetapes and then inlaying these tapes together within amain body knitted fabric (e.g., STF inlay 43 in FIG. 20)allows ultra-lightweight fabrics to be knitted with thesetapes aligning fiber for extra strength where needed. In-laying, flat STF has several benefits, including creatinga desirable mechanical performance, while improvingresin impregnation, with straighter more uni-directionalfibers where needed and reducing the amount of excessresin. According to embodiments of the present disclo-sure, STF fibers may be integrated into a fiber reinforcingstructure, horizontally, vertically, and diagonally by knit-ting, inlaying 44, floating, and tucking, by utilizing the un-spooling feed system (73 in FIG. 17). FIG. 17 shows thearrangement of multiple spool devices on an exemplaryknitting machine in accordance with an embodiment ofthe present disclosure.[0063] The V-bed three-dimensional knitting processmay create multiple structures in the same panel withspecific structures or combinations of differing construc-tions, varying thicknesses, and varying resins where re-quired. FIG. 24 shows knitted FRP vehicle panel withappendages, void and miter of corrugations (double bedfabrics). Openings 51, pockets, appendages 56, ventila-tion, sub structures, super structures, and liners may alsobe knitted in the same knitting process. The machine maymiter fabrics together in desired strategic angles 57. Eachpanel structure may have several zones, including a lead-ing edge, a central panel and a top edge, which may beknitted in order or partially at different times, dependingon construction. Appendages, liners, and/or dimensional

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reinforcement constructions may be perpendicular oraligned to the grain of the main body structure. A panelstructure may be a solitary material structure, or it mayhave two or more fields of intarsia, FIG. 15 shows anexemplary intarsia structure generated in a knitting proc-ess in accordance with an embodiment of the presentdisclosure. In intarsia, a material knits solely in one fieldbut not others. Or a material may knit in some fields, butnot all. A field may be inset, surrounded on all sides byone or more fields, or it may extend the length of thepanel. There may be two intarsia fields in a panel, or asmany as knitting feeders allow. The fields are joined bya knitted, tucked or transferred stitch. One or more edgesof each field may be straight or irregularly shaped. Oneor more edges of the panel may be straight or irregularlyshaped.[0064] FIG. 16 shows an exemplary weft knit warp in-sert and spacer structure generated in a knitting processin accordance with an embodiment of the present disclo-sure. The fabric structure, e.g., a spacer fabric, has aface fabric structure 75 and a rear fabric structure 74.The two structures are connected together by a seriesof tuck X’s or V’s of an internal material 76. The spacer76 may have different properties on the face fabric fromthe rear fabric. The internal material may have a differentproperty entirely form the other two materials, or may bea combination of materials having a specific performancecharacteristic, when combined. One or more parts of thespacer may contain fields of intarsia, with each intarsiamaterial having differing colors or properties.[0065] A polymer reinforcing panel structure, may itselfhave additional reinforcing structures. These may be inthe form a weft knit warped material inserted vertically,horizontally, and diagonally into a fabric panel or a hori-zontal inlay. The weft knit warp may knit tuck or inlay inany combination of stitch structures. It may be asymmet-rical 77 in a fabric panel. Two warp structures may travelin different patterns 78 and 79 in a panel.[0066] FIG. 29 shows fiber reinforced panels in a ma-rine application produced in a knitting process in accord-ance with an embodiment of the present disclosure; theweft knit warp insert mathematically and proportionallyto the panel dimensions and function. Warp structuresmay also overlap each other (shown by overlapping re-inforcing group of strands 83 in FIG. 29). A warp structuremay lay on the surface of one side of a spacer. It maytravel in the middle of the fabric unseen on either face.A warp structure may also travel from one face to anotherin any direction or combination of directions, dependentupon the desired aesthetic or performance characteristicof the polymer reinforcing structure.[0067] FIG. 25 shows the configuration of an autarkicfeeder in accordance with an embodiment of the presentdisclosure. The autarkic feeder may knit inlay, create anintarsia field, and create a plaited structure in the samerow of knitting. Appendage, liner, or reinforcement struc-tured fabric may be aligned and pressed together intozones to constitute a strategically plied group of layers

or zones to create the three-dimensionally shaped poly-mer reinforcing panel or it may be separated into separatesmaller components by knitting in separating strandsconnecting successive layers of the three dimensionallyshaped polymer reinforcing panel. Current needle bedwidths of V-bed flat knitting machines are limited to amaximum of ninety-six inches. Dependent on the config-uration, the actual width of the knitted panel constructionmay be wider or narrower in the case of rib layouts cre-ating an accordion-like structure.[0068] To create panel constructions larger than thelimit of the needle bed, panels may be joined. FIG. 26shows an overlapped panel join and spline edge that arecreated in a knitting process in accordance with an em-bodiment of the present disclosure. FIG. 26 shows onesuch type of overlapped join 62, where one panel of pol-ymer reinforcing fiber structure 65, has correspondinggrooves to a second joining panel 66. The edges of thepanels may be finished in a variety of configurations toaccommodate many types of joins ,to other panels and/oradditional hardware such as splines 64. The edge of apanel corresponding to a spline, may have a groove knit-ted into it, corresponding to the shape of the spline, soas to allow a spline to slide onto the finished FRP paneledge 63, securing the attachment. There are many rea-sons for attaching splines or other hardware to 3 dimen-sional FRP panels including for aesthetic purposes.[0069] FIG. 27 shows three-dimensionally shaped jac-quard panels using 2 colors of polymer reinforcing fiberthat are generated in a knitting process in accordancewith an embodiment of the present disclosure. FIG. 27illustrates FRP jacquard panels used in the interior 35and exterior of a vehicle. Each FRP jacquard panel ismade by utilizing a base fiber 33 and an accent fiber 34which are reinforcing fibers of different colors. The twotypes of fibers are knitted together to the predefinedshape of each panel and arranged into a 2-color jacquard32.[0070] In addition to aesthetics, there are other pur-poses for creating geometric patterns in FRP panels.FIG. 28 illustrates various exemplary aircraft designs thatare implemented by utilizing carbon fiber structuresthrough a knitting process in accordance with an embod-iment of the present disclosure. Inlaying, knitting or em-bedding one or more polymer reinforcing fibers in geo-metric configurations may not only add to strength of apanel, but may also assist in damping vibration and indispersing heat and friction build up. For example, theceramic fiber 36 is inlayed geometrically into a carbonfiber 38 structure using a curved interlacing Fibonaccilayout 37, which is mathematically and proportionally ar-ranged by the knitting machine to the friction distribution,airflow across an aircraft wing, and shape of the wing 40.The carbon fiber inlayed with ceramic fiber may dampenvibration and absorb excessive heat.[0071] In another example, the ceramic fibers 36 is in-layed geometrically and proportionally into a sphericalcarbon fibers 38 structure using a spiral Fibonacci layout

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for a helicopter or drone nose; the inlay proportional tothe direct friction distribution ,airflow and shape. The ce-ramic fibers inlayed with the spherical carbon fibers mayeffectively absorb vibration and dissipate heat. The or-ganic shaped aircraft 42, which flies at extraordinarilyhigh speeds, may have a fuselage knit with an elongatedspiral layout of embedded vibration dampening material,concentrated at the nose cone and strategically expand-ed out over the wings, concentrated aerodynamically atpoints of most air friction. The same principle may beapplied to knitting propeller blades 41 three dimension-ally to shape on the knitting machine. FIG. 20 demon-strates a detailed view of an exemplary aircraft panel thatis knitted to shape in a unitary construction 61 in accord-ance with an embodiment of the present disclosure. Theunitary construction 61 is knitted with strategically placedvoids 51, corrugated structures 45, horizontal reinforcinginlaid STF material 43, and a group of warp inlay strands44, which are geometrically positioned in proportion tothe length width and dynamic stress points in the panel.[0072] FIG. 29 demonstrates various exemplary pan-els in marine applications that are knitted to shape inaccordance with an embodiment of the present disclo-sure. Illustrated includes a half-gauge tubular knittedmast 81 in which the tubular structure is graduated indiameter 80, with an overlapping warp 79 travelingaround the mast pole from front bed to back bed. Thesailboat hull 87 has a linear warp reinforcing structure,and fin keel 86 in an organic shape, with a reinforcingwarp embedded in a Fibonacci layout 37 in proportion tothe curves of the keel. A boat may have two panels joinedin an overlapping seam 89, each panel having a grain inperpendicular directions. The hull is knitted turned cloth82 (with turn cloth grain) with overlapping reinforcingwarp strands 83. The bow 90 has a vertical miter 88 andoverlapping reinforcing warp structures positioned to ab-sorbed water and debris impact and vibration. A surf-board composite structure may be knitted as a half gaugetube to shape 91 with narrowing and widening of a jac-quard 32, and also have a reinforcing intarsia tube struc-tured edge. The surfboard has a unitary construction 91with linear warp reinforcing strands 84. A canoe shell isknitted turned cloth 82, with overlapping reinforcing warpstrands 83, strategically positioned for the dimensions ofthe shell and performance of the shell.[0073] Three dimensionally shaped polymer reinforc-ing panels may also be knitted from oxidized acrylicstrands. Following the knitting process, the knitted struc-tures are then heated to carbonize the strands, and aresin is injected. Any embedded ceramics would survivethe process. A three-dimensionally knitted carbon fiberfabric polymer reinforcing panel may be embedded in acarbon template by carbon vapor deposition to form thethree dimensionally shaped polymer reinforcing panel,and then heated to carbonize the yarn. A stack of polymerreinforcing fiber matrix fiber fabric vehicle panels may beembedded in a carbon matrix by carbon vapor depositionto form a vehicle panel.

[0074] A stack of three-dimensionally knitted polymerreinforcing fiber matrix fabric panel components may beembedded in a carbon matrix by carbon vapor depositionto form a vehicle panel.[0075] After the knitting step, a fully shaped polymerreinforcing panel can be further processed in one of sev-eral ways determined by the engineering purpose. Suchexamples of post process are resin transfer molding mod-ified lay-up molding, pressure molding, compressionmolding, vacuum-molding amongst others.[0076] The panel is further assembled onto a panelliner and the fully formed vehicle panel material attachedto the hardware to form the completed vehicle panel. Thisprocess advantageously eliminates all the compositematerial cutting and greatly reduces the assembly steps.It may eliminate the layering and sub assembly steps ofthe typical vehicle panel manufacturing process, andgreatly reduce the assembly time and costs associatedwith creating new vehicle designs and retooling the man-ufacturing process for new designs, new styles and dif-ferent vehicle types. Rather, the pattern program may bereconfigured for each change in design and a separateknitting program must be used for each desired vehiclepanel engineering change order. Similarly, fewer raw re-inforcement materials are kept in inventory to accommo-date desired changes in styling, structure, and engineer-ing.[0077] A weft or V-bed knitting a fully-shaped three-dimensional fiber reinforced vehicle panel with complete-ly finished edges may only require stocking of the rein-forcing fiber yarn strands only. The reinforcing textile fab-ric is created at the same time as the product is knitted,with only a few strands of waste. The designs, materialconfiguration, textures, structures, performance charac-teristics, and any combinations of performance or aes-thetic options may be changed at will by adjusting, mod-ifying, or reconfiguring or recreating a software programused to control the knitting process.[0078] In some embodiments, additional materials areintegrated to a panel in various directions through a warp-ing integration. An inlay feeder or an autarkic feeder maycreate a warp system on a weft V-bed knitting machine.The warp strands inserted may act as a reinforcing group,adding additional strength, additional stretch, conductiv-ity or interactive material such as a shape memory alloy,stretch memory alloy, resistance wire, ceramic, or otherspecific performance characteristics to one or morezones of the three-dimensional fully-shaped vehicle pan-el. An example of this is a door panel or a seat backstructure requiring no lateral or back-and-forth move-ment or vibration of the material to maintain the effectivestructure during use at a multiplicity of velocities.[0079] The machine memory system may also storeinstructions for automatically knitting additional polymerreinforcing fiber panels individually or in a sequential pro-duction manner with multiple panels linked or daisychained together through a strand. The panels may allhave the warp of the modified standard feeders with the

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crochet/warp pattern guide, containing the plurality ofstrands. Knitting panels sequentially on the same knittingmachine allows for the same lots of materials to be usedin the same vehicle, for easy tracing of all materials andcomponents as well as having uniformed material quality,consistency, and the same machine calibrations through-out the vehicle panel system.[0080] As mentioned above, the knitting machine maybe any type of sophisticated knitting machine with two ormore needle beds. For example, one such knitting ma-chine is a Stoll CMS MTB knitting V-bed machine capableof high-speed intricate weft knitting techniques and op-erations. Another such knitting machine is the Stoll CMSADF knitting V-bed machine capable of intricate weft,warp, inlay, Ikat, and other specialized knitting tech-niques and operations due to the independent nature ofthe yarn feeder 20 from the knitting cam box.[0081] In some embodiments, the knitting machinemay mechanically manipulate a plurality of strands of thefully finished three-dimensionally knitted main panelbody during a knitting process to form a predefined, three-dimensional shaped polymer reinforcing panel. The knit-ting process may be an intarsia knitting process in whichmultiple intarsia elements are knitted and joined to formthe various components and structures in the polymerreinforcing panel.[0082] Modern vehicles have organic shapes for func-tion, aesthetics, safety, and aerodynamics. Electric ve-hicles have a unique challenge to achieve comfort, safetyaesthetics and aerodynamics, while delivering a fair bat-tery life range. Material weight impacts the range of mo-bility, and therefore manufacturers have a great need todevelop light weight, safety, functionality and aesthetics.A knitting process according to embodiments of thepresent disclosure can produce a strong multi-task func-tional component made of composite materials and ca-pable of being organically shaped to fit a mold.[0083] A three-dimensional shape of the fully-shapedpolymer reinforcing fiber panel may include a concaveor convex form disposed, while also creating a void forinserting additional hardware structures, sensors, Lidar,facial recognition, navigation, and other smart featureshoused in the various panels. For knitting thin compo-nents, e.g., narrower than the gap of the needle bed 2.54mm, the knitting machine may be programmed to stopat a certain part of the knitting process, and the monitormay display an instruction on the screen for an operatoror robot to insert a specific component in a designatedplace in the needle bed gap. When the component isinserted into the designated space, the operator or therobot lifts the handle on the machine and the knitting proc-ess continues. This process may be repeated as manytimes in the knitting process to complete the configurationof the panel. A three-dimensional shape also may en-compass substantially planar and/or convex regions ofthe vehicle sides and front panels, the nose and tail ofan aircraft, and hood or trunk panel on an automobile.For example in the nose and tail of an aircraft, there may

be specific aerodynamic features incorporated in thethree-dimensional configuration. The front and rear (e.g.,the nose and the tail) might have extra layers of impactstructure. The lateral side panels and medial sides mayinclude knitted intarsia elements for lighting or othersmart applications.[0084] The knitting machine itself may be configuredto interloop a plurality of first strands with a plurality ofsecond strands, and any number of additional strands,to form a predefined three-dimensional shape which maybe a combination of shapes, textures, and structures thatall are part of, or contribute to the shape of the polymerreinforcing panel. The machine also may mechanicallymanipulate other strands, or different portions of thesame strand, of the unitary textile construction to formthe above-mentioned predefined generally curved, com-plex or planar shapes in the complete fiber reinforcingpanel and/or predefined three-dimensional convex/con-cave shapes, edges, structures, insulation, rigid areas,impact zones, corrugation, electrical channels, embed-ded wiring, and other knitted structures in the three-di-mensional polymer reinforcing structure. The lattershapes may correspond generally with the exterior pan-els and/or the respective edges or other portions of thevehicle interior panels.[0085] During the knitting process, the knitting ma-chine knits a fully formed unitary polymer reinforcing pan-el to form the respective components of the three dimen-sional fully finished panel with completely finished edges.For instance, the knitting machine knits and constructsadjacent structures, including fold over insulation for aninterior assembly, adds the hardware attachment ap-pendages as inserts as the machine progresses, thenmoves the stitches for the hardware appendages to analternative needle bed and attaches the hardware ap-pendage stitches to the reverse side of the panel edge,which have respective predefined shapes and patterns.In this method of manufacturing, the hardware append-age stitches may be formed horizontally and attached bythe machine to appear perpendicular to the body fabricof the panel, in order for the machine to close or seal theedges with knitting loops, thereby resulting in a seamlessstructure. The hardware appendage area may incorpo-rate a functional design, combination of strands, or pat-tern lines, for reinforcement, stress and strain manage-ment.[0086] According to embodiments of the present dis-closure, a polymer reinforcing fiber panel structure (suchas that used in vehicle assembly) may be created on aknitting machine in a knitted construction with a singlelayer or multiple layers, completely fashioned to shapeby the machinery, with no cutting, no sewing, and noexcess trimming of the polymer reinforcing panel or pol-ymer reinforcing panel layers. For example, the knittedconfiguration may be a spacer, which is a fabric havinga single faced fabric made on one bed and a reversesingle faced fabric made on the opposing V-bed and hav-ing both single fabrics being connected by an internal

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strand/or combination of strands configured in "V" or "X"patterns of interlacing between the two faces. The twoface fabrics are connected by tucking or knitting selectedneedles on each bed. The frequency and configurationof the "V," "X," "W" or other pattern of interlacing betweenthe two face fabrics correlates with the space size vari-ation characteristics between the face fabrics, otherwiseknown as cushioning.[0087] With regard to the method for knitting the fullyshaped three-dimensional polymer reinforcing fiber pan-el, in some embodiments, the knitted construction mayhave a single layer or multiple layer fully-shaped append-age reinforcement and/ or liner areas. Each layer or lineris completely fashioned to shape by the machinery, withno cutting, no sewing, and no excess trimming of theappendage or panel layers. For example, the configura-tion may be knitted as an attached but separately-shapedleading edge aesthetic or reinforcement shape with a per-formance or aesthetic strand, aramid or para-aramidstrand and/or a strand combined with a thermoplasticadhesive strand, where the shape is connected to theleading edge of the main body polymer reinforcing paneland is folded over or under the three-dimensional poly-mer reinforcing fiber panel body and assembled in anafter-process related to the molding and/or assemblyprocess. The configuration may be knitted as an attachedbut separately shaped hardware attachment areas,which may have an aesthetic and/or reinforcement shapewith a performance or aesthetic strand, aramid or para-aramid strand and/or a strand combined with a thermo-plastic adhesive strand, where the shape is connectedto the interior of the panel and is folded over or under thefully shaped three-dimensional vehicle panel body andassembled in an after-process related to the moldingand/or assembly process.[0088] The configuration may be knitted as an attachedbut separately shaped super structure, which may havean aesthetic or reinforcement shape with a performanceor aesthetic strand, aramid or para-aramid strand and/ora strand combined with a thermoplastic adhesive strand,where the shape is connected to the center of the vehiclepanel and is folded into the fully shaped three-dimension-al vehicle panel body and assembled in an after-processrelated to the molding and/ or assembly process.[0089] The configuration may be knitted as an attachedbut separately shaped under structure, which may havean aesthetic or reinforcement shape with a performanceor aesthetic strand, aramid or para-aramid strand and/ora strand combined with a thermoplastic adhesive strand,where the shape is connected to the interior of the vehiclepanel and is folded over into the underside of the fullyshaped three-dimensional polymer reinforcing fiber ve-hicle panel body and assembled in an after-process re-lated to the molding and/or assembly process.[0090] The configuration may be knitted as an attachedbut separately shaped lateral and/or medial appendage,which may have an aesthetic, insulative, or reinforcementshape with a performance or aesthetic strand, aramid or

para-aramid strand and/or a strand combined with a ther-moplastic adhesive strand, where the shape is connectedto the interior or exterior region of the vehicle panel andis folded over or under the fully shaped three-dimensionalvehicle panel body and assembled in an after-processrelated to the molding and/or assembly process.[0091] The configuration may be knitted as an attachedbut separately shaped insulation component which maybe knitted to shape with a performance, cushioning,spacer or aesthetic strand, aramid or para-aramid strandand/or a strand combined with a thermoplastic adhesivestrand, where the insulation/acoustic shape is connectedto the a point on vehicle panel, which can be folded overor under the fully shaped three-dimensional vehicle panelbody and assembled in an post process related to themolding and/or assembly process.[0092] The configuration may be knitted as an attachedbut separately shaped full panel liner, which may havean aesthetic or reinforcement shape with a performanceor aesthetic strand, aramid or para-aramid strand and/ora strand combined with a thermoplastic adhesive strand,where the shape is connected to the vehicle panel in theknitting process and is folded over or under the fullyshaped three-dimensional vehicle panel body and as-sembled in an after-process related to the molding and/orassembly process.[0093] The configuration may be knitted as an attachedbut separately shaped strap, tab, closure system, web-bing or other shaped appendage, which may have anaesthetic or reinforcement shape with a performance oraesthetic strand, aramid or para-aramid strand and/or astrand combined with a thermoplastic adhesive strand,where the shape is connected to a point on the fullyshaped three-dimensional vehicle panel body and as-sembled in a post process related to the molding and/orassembly process.[0094] In some embodiments, the knitted constructionmay be a single unit, knitted one at a time, or may be oneunit of a strip of units that are ’"daisy chained" sequen-tially, for example, interconnected in the manner of: paneledge to panel edge; top side to bottom side; right side toleft side; or any point or combination of points on thevehicle panel to another adjacent or opposing point.[0095] In some embodiments, different knitted compo-nents of a knitted vehicle panel are contiguous and con-tinuous with one another, being formed from the pluralityof strands that make up the unitary textile material in pre-preg form, or non-pre-preg format. Indeed, many of theindividual strands may span the length of a vehicle panel(e.g., from the top to the bottom or from right to left) andmay be inter-looped in specific regions of the vehicle pan-el, thereby integrated to form the different knit patternsof the vehicle panel. Thus, as one example, a knittingmachine may inter-loop a first strand with a second strandnear the bottom. The first strand may continue into a ver-tical element through the center and one side. In the sidearea, that strand may be inter-looped or combined withadditional strands within the knit pattern to form cushion-

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ing insulation on the reverse side. The same strand mayextend into and be inter-looped with yet other strands toprovide reinforcement in the knit pattern in one or severalhardware appendages. The same strand may extendalong the entire vehicle panel with minimal waste. Byutilizing the same yarns throughout the knitting process,it reduces the wastage of the elemental yarn materialsand other materials while creating a robust reinforcementstructure with completely finished edges of the vehiclepanel, requiring no cutting, sewing, or trimming of thevehicle panel.[0096] According to the embodiments of the presentdisclosure, a knitting process alone can produce ashaped three-dimensional polymer reinforcing fiber ve-hicle panel in multiple components or in a unitary con-struction. The resultant panel or panel complex can bea body of the vehicle panel, insulation, super structuresand interior structures, hardware appendages, respec-tive apertures and as well as the different componentsof the vehicle panel in respective zones with their respec-tive structures and patterns. The knitting process can beperformed in an automated manner without requiring di-rect manual, human manipulation of any strands in themachine.[0097] Whether to produce a three-dimensional com-ponent panel complex or a unitary construction of a fullyshaped three-dimensional polymer reinforcing fiber pan-el, the material fabric and/or knit configuration, and inparticular its multiple strands, may be machine-manipu-lated to provide different knit patterns. During the knittingprocess, the knitting machine effectively knits a pluralityof strands individually and/or collectively to form the dif-ferent regions of the fully shaped three-dimensional ve-hicle panel and/or component in a unitary construction.For example, a panel includes the first knit region of theleading edge, the second knit region the central panel,the impact areas, the curved edges of the apertures, thehardware appendages and/or insulation attachment ar-ea, as well as the end stitches of the liner panel used toattach to the corresponding sides of the vehicle panelexterior surface.[0098] In some embodiments, a majority of the vehiclepanel may be weft knitted, and may include multiple struc-tural elements, such as a vertical tubular, a horizontalinlay, vertical inlay elements, pockets, housing struc-tures, and embedded materials as described above. Theknitting machine creates all of these different compo-nents and patterns in an autmated mechanized processusing multiple needles through which the yarn, filament,inlay, extrusion or other element is dispensed and includ-ed in the fully shaped three-dimensional vehicle panel.Effectively, the plurality of strands is put in place via me-chanical manipulation of the respective needles of theknitting machine, within the three-dimensional vehiclepanel. None of the strands are subject to direct manualhuman manipulation to form the pocket body, let aloneany of its three-dimensional shapes or components.[0099] Throughout the knitting process, the knitting

machine knits different regions and different patterns. Asmentioned above, it may knit a first pattern, a secondpattern, and successive patterns, forming the shapedstructure therein, as well as the optional exterior ele-ments, as well as the optional interior elements, addition-al structural details and all regions to create a functionalvehicle panel. In constructing the different patterns, theknitting machine may change the fabric density by vary-ing the number of strands, courses "rows" and/or wales"stitches" in a given region as well as in different regionsof the three-dimensional vehicle panel. For example, theknitting machine may manipulate the strands so that thedensity of strands in the perimeter edge is smaller thanthe density in the insulation region and other regions tofacilitate assembly. The density of strands in the edgearea may likewise be greater than the density in the bot-tom center and other regions, to enhance stiffness andprevent the panel from vibrating.[0100] Where the edges, constructed from the pluralityof strands of the first material interfaces or transitions tothe other components such as the hardware appendageknitted pattern for assembling ease, third pattern foracoustic/insulation cushioning, or aperture pattern for re-inforcement, the strands of the first material may be in-terloped and interlaced directly with the knitted strandsof the adjacent region of the second material. To achievethis, different needles of the machine feed and inter-loopthe different materials in the respective different locationsand one of two needle beds and transfer cams may movestitches from one area to another. One of two additionaland alternative needle beds may attach loops from onelocation of fabric structure to another. After a fully shapedthree-dimensional vehicle panel is knitted and completedby the knitting machine, it may be removed from the knit-ting machine and later joined with a liner component andother three-dimensional knitted components, and ulti-mately a chassis configuration in a desired manner asdescribed herein.[0101] In some embodiments, a knitting machine maybe programmed or otherwise controlled to generate in-dividual stand-alone fully shaped three-dimensional ve-hicle panels, or a daisy-chained strip of fully shapedthree-dimensional vehicle panels. For example a daisychain includes the first, the second, the third and morecomplete fully shaped three-dimensional vehicle panels,each knitted in a manner similar to that described above.[0102] For instance, the machine may knit a first fullyshaped three-dimensional vehicle panel, second fullyshaped three-dimensional vehicle, and third fully shapedthree-dimensional vehicle, or any other number of fullyshaped three-dimensional vehicle panel. In some em-bodiments, each three-dimensional vehicle panel knitpattern may be different from the patterns of the respec-tive subsequent three-dimensional vehicle panels. Ofcourse, the patterns may be changed to be similar tothose of the respective initial three-dimensional vehiclepanel if desired within the edge interface as well.[0103] In some embodiments, the knitting machine, or

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other automated panel assembly machine, may be con-trolled by a controller to produce the daisy-chained stripof fully shaped three-dimensional vehicle panels. Thecontroller may be any conventional processor, computeror other computing device. The controller may be elec-trically coupled to the machine, and may be in commu-nication with a memory, a data storage module, a net-work, a server, or other construct that may store and/ortransfer data. That data may be particular type of datarelated to knitting vehicle panels. For example, the datamay include a profile of a first fully shaped three-dimen-sional vehicle panel, specifying one or more particularknitting patterns or other patterns and the instructions tocontrol the knitting process to create such a panel. Thedata for a fully shaped three-dimensional vehicle panelmay be implemented, accessed and/or utilized by themachine, in the form of a code, program and/or otherdirective. The fully shaped three-dimensional vehiclepanel data, when executed, ultimately may generate inthe fully shaped three-dimensional polymer reinforcingfiber vehicle panel features such as: the predefined three-dimensional shape; the position, dimension and/or depthof a specific area of a panel structure; the position of anapex and compound curve of the vehicle panel; the lengthand location of an aperture with interior edge corrugationstructure; the position and dimension of various edgesand calibration marks for assembly to the interior three-dimensionally knitted components, hardware, and chas-sis; the position and dimension of a leading edge; theposition and dimension the corrugation, acoustic cush-ioning/ insulation areas and/or lip edge of the vehicle pan-el; the lateral and vertical stiffness of the hardware ap-pendage structure; the minimum and maximum widthand length of the fully shaped three-dimensional vehiclepanel; the side to side curvature of the aperture, leadingedge, central panel, interior elements, embedded ele-ments, and the like.[0104] In some embodiment, a panel configuration,can be converted to digital data by using a body scannerto scan a model, e.g., to generate a point cloud. Thescanned data can be interpreted, input manually, or oth-erwise digitally gathered and combined with the polymerreinforcing structure programming data by the V-bed knit-ting machine or computer coupling system. The V-bedknitting machine or computer coupling system automat-ically converts the user selection data into the form of acode or set of data codes to configure the user’s desiredmodifications to the original three-dimensional polymerreinforcing structure computerized knitting program. Thecontrol or other device may interpret the raw data, scan,or point cloud and reduce the data to code usable by theknitting machine .The v-bed machine accesses the con-verted data code to create knitting production instruc-tions, which are then accessed and implemented by theV-bed knitting machine to create one or more desiredcustomized aesthetic variations and/or customized func-tional variations of the original seamless three-dimen-sional polymer reinforcing structure.

[0105] The controller and/or the automated vehiclepanel knitting/assembly machine may access the fullyshaped three-dimensional vehicle panel data to therebycontrol the knitting/assembly machine and produce astrip of fully shaped three-dimensional vehicle panels,sequentially, in a desired number and configuration.Each of the fully shaped three-dimensional vehicle pan-els may include a substantially identical predefined three-dimensional shape, and may have virtually identicalphysical features, such as those enumerated above inconnection with the fully shaped three-dimensional ve-hicle panel data. Alternatively, if the machine is config-ured to produce only a single fully shaped three-dimen-sional vehicle panel, the machine may be controlled bythe controller, which may utilize the first fully shapedthree-dimensional vehicle panel data to produce a fullyshaped three-dimensional vehicle panel having featuresthat correspond to the panel configuration specified byfirst fully shaped three-dimensional vehicle panel data.[0106] In turn, a user may experiment with those dif-ferent fully shaped three-dimensional vehicle panel pro-files, sizes, and/or styles, and select the one that bestsuits their preferences for assembly. In addition, if a userhas a particular vehicle profile preference, that profile ofa particular fully shaped three-dimensional vehicle panelmay be stored in a database. When the user damagestheir first fully shaped three-dimensional vehicle panel,they may request another fully shaped three-dimensionalvehicle panel, identical to the first fully shaped three-di-mensional vehicle panel, and it is produced again. Thismay enhance the experience of the user and of the man-ufacturer, since no parts need to be inventoried or stored.Also, the manufacturer need not go through extensiveselection process and time period to locate a fully shapedthree-dimensional vehicle panel that performs as de-sired. Instead, upon purchase of the new fully shapedthree-dimensional vehicle panel combination, the fullyshaped three-dimensional vehicle panel will be producedon-demand, and consistently perform as expected forthe user. The panels may have aesthetic designs or jac-quard knitted into the main body. These designs or jac-quards may be customized by the user, and subsequent-ly knitted by the machine.[0107] In the conventional art, fiber reinforced compos-ite vehicle panels are produced by forming two-dimen-sional cut and assembled shaped vehicle panels or three-dimensional semi-finished vehicle panels. The individualpieces or semi-finished vehicle panels typically requirewaste. Warp knitting or weft knitting roll goods, then cut-ting and assembling to shape, also requires waste.[0108] According to embodiments of the present dis-closure, to knit fully shaped three-dimensional vehiclepanels, the start, the interface of the leading-edge ele-ment is only a strand, or a couple strands waste and adecoupling strand, which protects the finished bottomedge "leading edge." In manufacturing an individual fullyshaped three-dimensional vehicle panel, the hardwareappendage structures, the aperture, and other edge ar-

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eas have no edge interface and therefore no waste sec-tion.[0109] In manufacturing a daisy-chained strip of fullyshaped three-dimensional vehicle panels, the next lead-ing-edge structure area has an edge interface strand pro-tecting the finished edge. The interface strand links upto bottom edge "leading edge interface strands of thenext fully shaped three-dimensional vehicle panel, sep-arated by a decoupling strand. This transition area maymimic or follow the curvature of the bottom edge "leadingedge" of a particular subsequent three-dimensional pol-ymer reinforcing panel structure or panel portion as de-sired. Therefore, there is no waste section and only a fewstrands waste per unit, which can be as low as less than1% of the total weight of the shaped three-dimensionalpolymer reinforcing panel structure.[0110] In one example, the respective edges, for ex-ample one leading edge structure knitted to the end ofthe unit and then subsequently to the next leading edge,may be joined with the edge interface strands in the formof a single pull stitch or strand. This pull stitch may bepulled by a machine or a human operator so that therespective edges separate from one another and/or theedge interface, thereby allowing one fully shaped three-dimensional vehicle panel to be removed from, or disso-ciated from, another fully shaped three-dimensional ve-hicle panel. Likewise, the edge interface may include oneor more pull strands that may be pulled via a machine orhuman operator to separate the lower edge from the edgeinterface.[0111] In some cases, where the subsequent edge("leading edge") of one fully shaped three-dimensionalvehicle panel is joined directly with the previous vehiclepanel edge "hardware appendage structure" of anotherfully shaped three-dimensional vehicle panel, a pullstrand at the edge interface may be pulled to separatethe second fully shaped three-dimensional vehicle panelfrom the first fully shaped three-dimensional vehicle pan-el.[0112] Another mechanism for separating the fullyshaped three-dimensional vehicle panels from the daisy-chained strip may include the use of a decoupling ele-ment. This decoupling element may decouple one fullyshaped three-dimensional polymer reinforcing fiber ve-hicle panel from the next, e.g., at the edge interface orrespective edges of the fully shaped three-dimensionalvehicle panels. The decoupling device may includeshears, pressurized steam, thermoplastic strand, or oth-er separating device or mechanism, which cuts, pulls, ormelts the thermoplastic separation strands across thelower edge ("leading edge") of each fully shaped three-dimensional polymer reinforcing panel. In so doing, thoseshears cut, the pressurized steam melts or evaporatesoff, the next adjacent and/or successive fully shapedthree-dimensional polymer reinforcing panel. The decou-pling element may make multiple cuts, multiple pulls, orsteaming traverses, one adjacent the polymer reinforcingpanel edge "hardware appendage structure" of each suc-

cessive fully shaped three-dimensional polymer reinforc-ing panel and/or adjacent the lower edge "leading edge"of the each successive fully shaped three-dimensionalpolymer reinforcing panel. In cases where the edge in-terface element is only a strand or a couple of strandswide, the decoupler may cut or steam melt across thisedge interface, thereby separating the respective edgesof the third and second fully shaped three-dimensionalpolymer reinforcing panels. From there, the fully shapedthree-dimensional polymer reinforcing panels may beplaced into a bin or other container for further processingon an individual basis. In some embodiments, a contin-uous strip of multiple fully shaped three-dimensional pol-ymer reinforcing panels may be rolled on a spool anddelivered to a manufacturer who may then mechanicallyor manually disassociate the individual fully shapedthree-dimensional polymer reinforcing panels from thedaisy-chained strip.[0113] Upon decoupling the individual fully shapedthree-dimensional polymer reinforcing panels, each ofthe fully shaped three-dimensional polymer reinforcingpanels generally retain their predefined three-dimension-al shapes resultant from the knitting process. For exam-ple, even upon decoupling, the individual panels will re-tain the concavity of the concave shape and/or contourof the leading edge, center panel, edges, aperture, andhardware appendage structure. Retaining its shape alsoassures that the fully shaped three-dimensional polymerreinforcing panel fits consistently into other after-processing tools and assembly equipment that is re-quired for manufacturing the finished polymer reinforcingpanel "3D panel" repeatedly and consistently.[0114] A fully shaped three-dimensional polymer rein-forcing panel daisy-chained strip may include panels ofvarying widths. For example, the machine may vary thewidths of the fully shaped three-dimensional polymer re-inforcing panels daisy-chained strip by size and/or indi-vidual fully shaped three-dimensional polymer reinforc-ing panels of the strip, interconnected with a strand. Forexample, the machine may mechanically manipulatestrands to generate fully shaped three-dimensional pol-ymer reinforcing panels along the strip that have a widthat their outermost lateral boundaries of the number ofneedles in the respective knitting machine. This is gen-erally the maximum width possible of the fully shapedthree-dimensional polymer reinforcing fiber panels strip,and along its length there is no limit. This maximum widthmay correspond to the region of the fully shaped three-dimensional polymer reinforcing panels as measuredacross the widest part of the polymer reinforcing panel.It also may be the maximum of width of any individualfully shaped three-dimensional polymer reinforcing fiberpanel component that is formed along the daisy-chainedstrip. The machine also may mechanically manipulatethe strands and the overall width of the daisy chainedstrip so that the daisy-chained strip includes a secondwidth, which is less than the first width. The second widthmay correspond generally to an individual three-dimen-

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sionally knitted polymer reinforcing panel component,such as a separate configuration of a: insulation compo-nents, hardware appendage structure tab system and/orother structural construction fitted in a molding or assem-bly after process. By precisely knitting the daisy-chainedstrip in the respective fully shaped three-dimensional pol-ymer reinforcing panels and componentry, thereby min-imal waste is generated from the process. This can betrue even when the individual fully shaped three-dimen-sional polymer reinforcing panels and components in thedaisy-chained strip have different configurations, e.g.,different widths. Without the knitting machine knitting afully shaped three-dimensional polymer reinforcing panelas a unit, or with the edge interface strand, the materialthat is usually knitted between the maximum width andthe smaller width with off the shelf machine builder soft-ware and CAD would otherwise be removed and discard-ed as waste. Further, removing this material would typi-cally require additional machinery and/or human inter-vention or manipulation.[0115] Frequently, a fabric, yarn, strand, or a textilestructure is used in a polymer reinforcing panel for thepurpose of adding an aesthetic element. A textile maybe defined as any manufacture from fibers, filaments, oryarns characterized by flexibility, fineness, and a highratio of length to thickness. The materials forming thepolymer reinforcing panel may be selected based uponthe properties of wear-resistance, flexibility, stretch, andair-permeability, for example. The fiber reinforced poly-mer reinforcing panel may be formed by a method ofcutting and sewing, therefore cut from numerous materialelements. Each may impart different properties to spe-cific portions of the polymer reinforcing panel. This cuttingand sewing method creates considerable waste, whichmay pose a challenge to recycle.[0116] Two-dimensionally shaped knitted textilesand/or three dimensionally knitted textiles, which aresemi-finished textiles used in polymer reinforcing panels,are generally joined at the hardware appendage structureor other parts of the panel. Generally, fiber reinforcedpolymer matrices provide lightweight, strong structuresthat are have great length to weight ratio. Use of roll goodfabrics, die cut, hand cut, two-dimensionally shaped knit-ted textiles and/or three dimensionally knitted textileswhich are semi-finished in polymer reinforcing panelstypically require many joins and additional labor. Seamsintroduce difficulties and limitations, to include difficultiesin manufacture and freedom of design, and unintendedfailure points in structural dynamics. In the case of fiberreinforced polymer matrices, joining these cut pieces cre-ated special handling issues for assemblers, and han-dlers. The join types and join types are limited to specifictechniques. With regard to durability, a polymer reinforc-ing panel formed entirely in one piece may advanta-geously have no seam weakness or seam failure points.[0117] To impart other properties to the fully finishedthree-dimensionally knitted polymer reinforcing panel, in-cluding durability, flexion, and impact-resistance, addi-

tional materials are typically combined or integrated inthe knitting process, including but not limited to reflective,fire resistant, thermoplastic, insulative, adhesive, rein-forcing, cushioning, aesthetic, conductive, electronic,and aesthetic for examples. Three-dimensionally knittinga polymer reinforcing panel to shape advantageously al-lows integrating specific materials into areas, the abilityto transition or blend the reinforcement, structural or otherspecific performance features, into desired regions to:reinforce against abrasion, impact, or other forms ofwear; provides seamless appearance; creates areas offlexion resistance/limitation or other performance fea-tures; better secures the polymer reinforcing panel to thechassis; and minimizes waste of materials.[0118] Generally, a knitted polymer reinforcing fiber el-ement with specific performance properties could be in-corporated into a wide variety of different articles. Exam-ples of articles that could incorporate a knitted Polymerreinforcing fiber element include, but are not limited to:automobiles, vans, truck, motor homes, campers, elec-tric vehicles, buses, carts, wagons, caravans, recreation-al vehicles, airplanes, drones, helicopters, gliders, hovercrafts, all-terrain vehicles, scooter, trains, rovers, boats,gondola, house boat, catamaran, row boat, racing sloop,sail boat, surfboard, water ski, sleds, bob sleds, golf carts,wheelbarrow, submersible, canoes, snow boards, kay-aks, toys, skates, bicycles, motor cycles, lawnmowers,tractors, strollers, chair lifts, fork lifts, bulldozers amuse-ment rides, playground equipment, helmets, protectivegear, as well as other similar articles. The significantweight savings, improved mechanical properties andthinner laminates may improve many vehicle compo-nents. Some examples include, but are not limited to themonocoque, exterior body, interior structures, interiorpanels, such as the dash and console, and floors, as wellas exterior panels of vehicles, and any other type of mo-bility, and transportation equipment. Additionally, insome embodiments, the article could be another type ofarticle including, but not limited to golf clubs, tennis rack-ets, hockey sticks, backpacks e.g., motorcycle bags, lap-top bags, etc., luggage, cargo holders, bins, covers, hel-mets, protective gear, medical devices, ballistic armor,as well as other articles that may or may not be worn.[0119] While various embodiments have been de-scribed, the description is intended to be exemplary, rath-er than limiting and it will be apparent to those of ordinaryskill in the art that many more embodiments, configura-tions, and implementations are possible and are withinthe scope of the embodiments. Accordingly, the embod-iments are not to be restricted except in light of the at-tached claims and their equivalents. Also, various mod-ifications and changes may be made within the scope ofthe attached claims. Other systems, methods, featuresand advantages of the embodiments will be, or will be-come, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed descrip-tion. It is intended that all such additional systems, meth-ods, features and advantages be included within this de-

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scription and this summary, be within the scope of theembodiments, and be protected by the following claims.

Claims

1. A method of manufacturing a polymer reinforcingpanel comprising one or more mathematically andproportionally shaped composite reinforced struc-tures by using a knitting machine, the method com-prising:

performing a knitting process on the knitting ma-chine to produce a first unitary knit constructionof three dimensions that defines a first reinforce-ment stitch structure,wherein the knitting process comprises knittingto shape one or more reinforcement yarns math-ematically and proportionally to form the first uni-tary knit construction,wherein the one or more reinforcement yarnscomprises polymer reinforcing fibers,wherein the first unitary knit construction com-prises a plurality of dimensional reinforcingstructure portions comprise: a leading edge ar-ea; a top edge and a central area,wherein each of the plurality of dimensional re-inforcing structure portions is knitted dimension-ally into shape through the knitting process andis connected to another portion by knitting stitch-es that are generated in the knitting process, andperforming a polymer composite process totransform the first reinforcement stitch structureinto a first composite polymer reinforced struc-ture comprised in polymer reinforcing panel.

2. The method of Claim 1, wherein the knitting processcomprises weft and/or weft knit warp knitting the oneor more reinforcement yarns mathematically andproportionally by operating two or more knitting bedson the knitting machine.

3. The method of Claim 1, wherein the first compositepolymer reinforced structure comprises a void,wherein the void is surrounded by the first unitaryknit construction and is formed through the knittingprocess.

4. The method of Claim 1, wherein the knitting processcomprises performing one or more of: knitting; float-ing; intarsia; plaiting; and inlaying on the one or morereinforcement yarns mathematically and proportion-ally.

5. The method of Claim 1, wherein the first unitary knitconstruction comprises one or more of: a corrugationarea; a tunnel; an insert segment; a mitered edge; avoid; a wedge; a short row; a pocket; a conductive

tube; cavity; a dimensional reinforcement structure;and an embedded wire assembly.

6. The method of Claim 1, wherein the first unitary knitconstruction comprises a main body and an append-age of the a first reinforcement stitch structure, andwherein further the knitting process further producesthe appendage of the polymer reinforcing panel byknitting a different yarn than the main body; and alive-hinged textile that connect the appendage tomain body.

7. The method of Claim 1, wherein the appendage isan interior liner layer of the first composite polymerreinforced structure.

8. The method of Claim 1, wherein the one or morereinforcement yarns comprise one or more of: a pol-ymer reinforcing strand; a sacrificial material strand;an adhesive material strand; a thermal plastic mate-rial strand; a vibration dampening strand; a heat dis-sipative strand; a wire assembly strand; and a non-polymer reinforcing strand.

9. The method of Claim 1, wherein the one or morereinforcement yarns comprise resin pre-impregnat-ed or comingled material strands.

10. The method of Claim 1, wherein the knitting processproduces a continuous chain of unitary knit construc-tions comprising the first unitary knit construction,wherein the sequence of unitary knit constructionshave different configurations or have an identicalconfiguration, and wherein further each unitary knitconstruction in the chain connects with anotherthrough live sacrificial strands that are generated inthe knitting process.

11. The method of Claim 1, wherein the first unitary knitconstruction comprises a vertical weft knit warp tex-tile section forming a plurality of strategically placedstrands mathematically and proportionally arrangedin the first reinforcement stitch structure, wherein theknitting process comprises knitting one or more func-tional strands into the plurality of layers, layer por-tions, components, and or plies.

12. The method of Claim 11, wherein the polymer com-posite process comprises pressing the plurality oflayers, layer portions, components, and or plies intoa mold structure to form the first composite polymerreinforced structure.

13. The method of Claim 11, wherein further the polymercomposite process comprises selectively heating amember of the plurality of layers, layer portions, com-ponents, and or plies.

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14. The method of Claim 11, wherein the plurality of pliescomprise one or more of: a functional structure; acorrugation areas; a tunnel; a pocket; a conductivetube; an insert segment; a mitered edge; a void; awedge; a short row; a vibration dampening strand;a heat dissipative strand; an aramid; a natural fiber;a para-aramid; a ceramic; a wire assembly strand;a warp knit weft insert; and a wire assembly.

15. The method of Claim 1, wherein the first unitary knitconstruction comprises knitted courses of differentlengths, and wherein further the knitting processcomprises inserting the one or more reinforcementyarns vertically, diagonally, horizontally and or anycombinations of directions in a mathematical andproportional manner along one or more knittedcourses,

16. The method of Claim 1, wherein the polymer rein-forcing fibers comprise one or more of: carbon fibersand oxidized fibers, and wherein further the polymercomposite process comprises heating the first rein-forcement stitch structure.

17. The method of Claim 1, wherein the first unitary knitconstruction comprises a section of multiple layers,layer portions, components, and or plies that havedifferent knit courses resulting from the knitting proc-ess, wherein the knitting process comprises gener-ating a connective knit structure to connected themultiple layers, layer portions, components, and orplies.

18. The method of Claim 17, wherein the knitting processcomprises knitting a thermal plastic adhesive strandto a select member of a plurality of layers, layer por-tions, components, and or ply to affix the select mem-ber to an adjacent member.

19. The method of Claim 17, wherein the multiple layers,layer portions, components, and or plies comprisepointelle mesh, lattice, and or apertures used foraligning.

20. The method of Claim 17, wherein the knitting processfurther comprises one or more functional yarns inaddition to the one or more reinforcement yarns toform the first unitary knit construction, wherein thefunctional yarns are resistant to the polymer com-posite process.

21. The method of Claim 1, wherein the first unitary knitconstruction comprises a knitted tubular structurehaving a graduated diameter, and wherein the knit-ting process comprises weft knit warp insert knittingthe one or more reinforcement yarns mathematicallyand proportionally arranged to form the knitted tubu-lar structure.

22. A polymer reinforcing panel comprising a first rein-forcement stitch structure in a form of a first unitaryknit construction in three dimensions, wherein thefirst unitary knit construction comprises a plurality ofportions comprising:

a leading edge area;a top edge; anda central area,wherein each of the plurality of portions is knittedto shape through a knitting process on a knittingmachine and connected to another portion byknitting stitches that are generated in the knittingprocess, wherein the first unitary knit construc-tion comprises stitches of one or more reinforce-ment yarns resulting from the knitting process,wherein each portion has a dynamic perform-ance structure and comprises a dimensionallyknit reinforcing structure arranged mathemati-cally and proportionally to an adjacent portionand in relation to functional performance of thepanel

23. The polymer reinforcing panel of Claim 22, whereinthe first unitary knit construction comprises stitchesgenerated from: knitting; floating; intarsia; plaiting;and inlaying on the one or more reinforcement yarnsin a mathematical and proportional arrangement.

24. The polymer reinforcing panel of Claim 22, whereinthe first unitary knit construction comprises one ormore of: a corrugation areas; a tunnel; an insert seg-ment; a mitered edge; a void; a wedge; a short row;a pocket; a conductive tube; a vibration dampeningstrand; a heat dissipative strand; a wire assemblystrand; a warp knit weft insert; and a wire assembly.

25. The polymer reinforcing panel of Claim 22, whereinthe first reinforcement stitch structure comprises amain body and an appendage of the a first reinforce-ment stitch structure, and wherein the appendage isconnected to the main body through a live-hingedtextile, wherein the live-hinged textile comprisesstitches generated from the knitting process.

26. The polymer reinforcing panel of Claim 22, whereinthe appendage is an interior liner layer of the firstcomposite polymer reinforced structure.

27. The polymer reinforcing panel of Claim 22, whereinthe one or more reinforcement yarns comprise oneor more of: a polymer reinforcing strand; a sacrificialmaterial strand; an adhesive material strand; a ther-mal plastic material strand; a vibration dampeningstrand; a heat dissipative strand; an aramid; a naturalfiber; a para-aramid; a ceramic; and a non-polymerreinforcing strand, and wherein further the one ormore reinforcement yarns comprise resin pre-im-

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pregnated material strands.

28. The polymer reinforcing panel of Claim 22, whereinthe first unitary knit construction comprises a verticalweft knit warp textile section forming one or a pluralityof strands inserted into a first reinforcement struc-ture, and wherein a plurality of layers, layer portions,components, and or plies are pressed together byusing a mold structure.

29. The polymer reinforcing panel of Claim 22, whereinthe first unitary knit construction comprises knittedcourses of different lengths, and the one or morereinforcement yarns are inserted vertically, horizon-tally, diagonally, n any combination of directionsalong one or more knitted courses through the knit-ting process.

30. The polymer reinforcing panel of Claim 22, whereinthe first unitary knit construction comprises a sectionof multiple layers, layer portions, components,and/or plies that have different knit courses resultingfrom the knitting process, wherein the multiple lay-ers, layer portions, components, and/or plies areconnected to each other through a connective knitstructure that is generated in the knitting process.

31. The polymer reinforcing panel of Claim 30, whereina select layer, layer portion, component, and/or plyof the multiple layers, layer portions, components,and/or plies comprises stitches of a thermal plasticadhesive strand, wherein the select layer, layer por-tion, component, and or ply bonds to an adjacentlayer through the stitches of the thermal plastic ad-hesive strand.

32. The polymer reinforcing panel of Claim 22, whereinthe first unitary knit construction comprises stitchesof a functional yarn that is resistant to a polymer com-posite process.

33. The polymer reinforcing panel of Claim 22, whereinthe first unitary knit construction comprises a knittedtubular structure having a graduated diameter.

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REFERENCES CITED IN THE DESCRIPTION

This list of references cited by the applicant is for the reader’s convenience only. It does not form part of the Europeanpatent document. Even though great care has been taken in compiling the references, errors or omissions cannot beexcluded and the EPO disclaims all liability in this regard.

Patent documents cited in the description

• US 62669255 A [0001]

Non-patent literature cited in the description

• DAVID J SPENCER. Cite: Knitting Technology.Leicester Polytechnic, UK, Pergamon Press, 1983[0011]

• CITE: KNITTING TECHNOLOGY. 1989 [0011]• CITE: KNITTING TECHNOLOGY. 2001, 43 [0011]