# US 11,077,644 B2 · Material systems and methods of manufacturing material systems

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- Number: US 11,077,644 B2
- Document ID: US11077644B2
- Status: Granted
- Kind: B2
- Application number: 15/378,931
- Filed: 2016-12-14
- Published: 2018-06-14
- Granted: 2021-08-03
- Earliest claimed: 2016-12-14
- Assignees: The Boeing Company
- Applicants: The Boeing Company
- Inventors: Patrick Bickford Stickler; Alexander Rubin
- Web page: https://patentgrep.com/patent/US11077644B2

## CPC

- B32B 15/14: next to a fibrous or filamentary layer
- B29C 43/56: Compression moulding under special conditions, e.g. vacuum
- B29C 65/02: by heating, with or without pressure
- B29C 66/712: {the composition of one of the parts to be joined being different from the composition of the other part}
- B29C 66/7212: {characterised by the composition of the fibres}
- B29C 66/7392: {characterised by the material of at least one of the parts being a thermoplastic}
- B29C 66/7422: {Aluminium or alloys of aluminium}
- B29C 66/7444: {Carbon}
- B29C 70/885: {with incorporated metallic wires, nets, films or plates (as lost heating elements B29C35/0272, B29C61/0625)}
- B32B 5/024: {Woven fabric}
- B32B 5/14: characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/10: at least one layer having inter-reactive properties
- B32B 15/043: {of metal (B32B15/01 takes precedence)}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/288: {comprising polyketones}
- B32B 37/06: characterised by the heating method
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B29C 66/7465: {Glass}
- B29C 2043/561: {under vacuum conditions}
- B29K 2071/00: Use of polyethers {, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof}, as moulding material
- B29K 2105/0872: {Prepregs}
- B29K 2105/12: of short lengths, e.g. chopped filaments, staple fibres or bristles
- B29K 2105/253: {Preform}
- B29K 2305/02: Aluminium
- B29K 2307/04: Carbon
- B29K 2309/08: Glass
- B29K 2705/02: Aluminium
- B29K 2995/0078: Shear strength
- B29L 2009/003: {comprising a metal layer}
- B32B 2260/021: Fibrous or filamentary layer
- B32B 2260/023: Two or more layers
- B32B 2260/046: Synthetic resin
- B32B 2262/101: Glass fibres
- B32B 2262/106: Carbon fibres, e.g. graphite fibres
- B32B 2305/076: Prepregs
- B32B 2311/24: Aluminium
- B32B 2313/04: Carbon
- B32B 2315/08: Glass
- B32B 2605/08: Cars
- B32B 2605/10: Trains
- B32B 2605/18: Aircraft
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A material system may include: an aluminum layer; a glass composite layer adjacent to the first aluminum layer; and a carbon composite layer adjacent to the first glass composite layer, and opposite to the first aluminum layer. A method of manufacturing a material system may include: stacking an aluminum layer, glass composite layer that may include thermoplastic prepreg plies, and carbon composite layer so that the aluminum layer is adjacent to the glass composite layer, and the glass composite layer is adjacent to the carbon composite layer; and consolidating the thermoplastic prepreg plies to soften the aluminum layer. A method of manufacturing a material system may include: stacking an aluminum layer, glass composite layer that comprises thermoplastic resin, and carbon composite layer so that the glass composite layer is between the aluminum and carbon composite layers; and adjusting temperature and pressure to consolidate the stack.

## Claims

### Claim 1

A material system, consisting of:
an aluminum layer;
a glass composite layer adjacent to the aluminum layer; and
a carbon composite layer adjacent to the glass composite layer, and opposite to the aluminum layer;
wherein the aluminum layer directly contacts the glass composite layer,
wherein the glass composite layer comprises first thermoplastic resin,
wherein the first thermoplastic resin bonds the aluminum layer and the glass composite layer,
wherein the carbon composite layer comprises at least consecutive first, second, and third carbon composite sublayers, with the second carbon composite sublayer in between the first and third carbon composite sublayers,
wherein the first carbon composite sublayer comprises fibers having first fiber orientation,
wherein the second carbon composite sublayer comprises fibers having second fiber orientation,
wherein the third carbon composite sublayer comprises fibers having third fiber orientation,
wherein the first fiber orientation is perpendicular to the second fiber orientation, and
wherein the third fiber orientation is halfway between the first and second fiber orientations.

### Claim 2 (depends on 1)

The system of claim 1, wherein the first thermoplastic resin bonds the glass composite layer and the carbon composite layer.

### Claim 3 (depends on 1)

The system of claim 1, wherein the first thermoplastic resin comprises polyetheretherketone (PEEK) or polyetherketoneketone (PEKK).

### Claim 4 (depends on 1)

The system of claim 1, wherein the carbon composite layer comprises second thermoplastic resin.

### Claim 5 (depends on 4)

The system of claim 4, wherein the second thermoplastic resin comprises polyetheretherketone (PEEK) or polyetherketoneketone (PEKK).

### Claim 6 (depends on 4)

The system of claim 4, wherein the first thermoplastic resin is the same as the second thermoplastic resin.

### Claim 7 (depends on 4)

The system of claim 4, wherein the first thermoplastic resin differs from the second thermoplastic resin.

### Claim 8 (depends on 1)

The system of claim 1, wherein the aluminum layer comprises a plurality of aluminum sublayers.

### Claim 9 (depends on 1)

The system of claim 1, wherein the glass composite layer comprises a plurality of glass composite sublayers.

### Claim 10 (depends on 1)

The system of claim 1, wherein the carbon composite layer further comprises a consecutive fourth carbon composite sublayer.

### Claim 11 (depends on 10)

The system of claim 10, wherein the fourth carbon composite sublayer comprises fibers having fourth fiber orientation, and
wherein the third fiber orientation is perpendicular to the fourth fiber orientation.

### Claim 12

A material system, consisting of:
an aluminum layer;
a first glass composite layer adjacent to the aluminum layer;
a carbon composite layer adjacent to the first glass composite layer, and opposite to the aluminum layer; and
a second glass composite layer adjacent to the carbon composite layer, and opposite to the first glass composite layer;
wherein the aluminum layer directly contacts the first glass composite layer,
wherein the first glass composite layer comprises first thermoplastic resin,
wherein the first thermoplastic resin bonds the aluminum layer and the first glass composite layer,
wherein the carbon composite layer comprises at least consecutive first, second, and third carbon composite sublayers,
wherein the first carbon composite sublayer comprises fibers having first fiber orientation,
wherein the second carbon composite sublayer comprises fibers having second fiber orientation,
wherein the third carbon composite sublayer comprises fibers having third fiber orientation,
wherein the first fiber orientation is perpendicular to the second fiber orientation, and
wherein the third fiber orientation is halfway between the first and second fiber orientations.

### Claim 13 (depends on 12)

The system of claim 12, wherein the first thermoplastic resin comprises polyetheretherketone (PEEK) or polyetherketoneketone (PEKK).

### Claim 14 (depends on 12)

The system of claim 12, wherein the carbon composite layer comprises second thermoplastic resin.

### Claim 15 (depends on 14)

The system of claim 14, wherein the second thermoplastic resin comprises polyetheretherketone (PEEK) or polyetherketoneketone (PEKK).

### Claim 16

A material system, consisting of:
a first aluminum layer;
a first glass composite layer adjacent to the first aluminum layer;
a carbon composite layer adjacent to the first glass composite layer, and opposite to the first aluminum layer;
a second glass composite layer adjacent to the carbon composite layer, and opposite to the first glass composite layer; and
a second aluminum layer adjacent to the second glass composite layer, and opposite to the carbon composite layer;
wherein the first aluminum layer directly contacts the first glass composite layer,
wherein the first glass composite layer comprises first thermoplastic resin,
wherein the first thermoplastic resin bonds the first aluminum layer and the first glass composite layer,
wherein the carbon composite layer comprises at least consecutive first, second, and third carbon composite sublayers,
wherein the first carbon composite sublayer comprises fibers having first fiber orientation,
wherein the second carbon composite sublayer comprises fibers having second fiber orientation,
wherein the third carbon composite sublayer comprises fibers having third fiber orientation,
wherein the first fiber orientation is perpendicular to the second fiber orientation, and
wherein the third fiber orientation is halfway between the first and second fiber orientations.

### Claim 17 (depends on 16)

The system of claim 16, wherein the first thermoplastic resin comprises polyetheretherketone (PEEK) or polyetherketoneketone (PEKK).

### Claim 18 (depends on 16)

The system of claim 16, wherein the carbon composite layer comprises second thermoplastic resin.

### Claim 19 (depends on 18)

The system of claim 18, wherein the second thermoplastic resin comprises polyetheretherketone (PEEK) or polyetherketoneketone (PEKK).

### Claim 20 (depends on 16)

The system of claim 16, wherein the glass composite layer comprises a plurality of glass composite sublayers.