# US 11,298,924 B2 · Component with bonded thermoplastic and thermoset layers

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- Number: US 11,298,924 B2
- Document ID: US11298924B2
- Status: Granted
- Kind: B2
- Application number: 16/131,939
- Filed: 2018-09-14
- Published: 2020-03-19
- Granted: 2022-04-12
- Earliest claimed: 2018-09-14
- Assignees: Rohr, Inc.
- Applicants: Rohr, Inc.
- Inventors: Teresa Kruckenberg
- Web page: https://patentgrep.com/patent/US11298924B2

## CPC

- 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 27/12: next to a fibrous or filamentary layer
- B29C 70/021: {Combinations of fibrous reinforcement and non-fibrous material}
- B32B 3/085: {spaced apart pieces on the surface of a layer}
- B32B 5/028: {Net structure, e.g. spaced apart filaments bonded at the crossing points}
- B32B 27/20: using fillers, pigments, thixotroping agents
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/34: comprising polyamides
- B32B 27/38: comprising epoxy resins
- B29L 2031/3076: {Aircrafts (blades, propellers B29L2031/08)}
- B32B 2250/02: 2 layers
- B32B 2250/03: 3 layers
- 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 2264/0214: Particles made of materials belonging to B32B27/00
- B32B 2264/0228: Vinyl resin particles, e.g. polyvinyl acetate, polyvinyl alcohol polymers or ethylene-vinyl acetate copolymers
- B32B 2264/108: Carbon, e.g. graphite particles
- 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)
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A component is provided that includes a multi-layer body configured with a thermoplastic layer, a thermoset layer and a scrim at an interface between the thermoplastic layer and the thermoset layer. The thermoplastic layer includes a plurality of reinforcement particles within a thermoplastic matrix. The thermoset layer is configured from or otherwise includes a thermoset matrix.

## Claims

### Claim 1

A component, comprising:
a multi-layer body configured with a thermoplastic layer, a thermoset layer and a scrim at an interface between the thermoplastic layer and the thermoset layer;
the thermoplastic layer comprising a plurality of reinforcement particles within a thermoplastic matrix, and the thermoplastic matrix comprising an amorphous thermoplastic;
the thermoset layer comprising fiber-reinforcement within a thermoset matrix, and the thermoset layer configured to form an exterior flow surface of the component; and
a thermoplastic structural support bonded to the thermoplastic layer, the thermoplastic structural support configured to structurally reinforce the multi-layer body.

### Claim 2 (depends on 1)

The component of claim 1, wherein
the plurality of reinforcement particles comprise a plurality of thermoplastic particles; and
a melting point of the thermoplastic matrix is less than a melting point of the plurality of thermoplastic particles.

### Claim 3 (depends on 1)

The component of claim 1, wherein the plurality of reinforcement particles comprise a plurality of polyether ether ketone particles.

### Claim 4 (depends on 1)

The component of claim 1, wherein the thermoplastic layer comprises about fifty percent by volume of the plurality of reinforcement particles and about fifty percent by volume of the thermoplastic matrix.

### Claim 5 (depends on 1)

The component of claim 1, wherein the thermoplastic layer further includes a plurality of carbon particles.

### Claim 6 (depends on 1)

The component of claim 1, wherein the scrim comprises at least one of carbon fibers or glass fibers.

### Claim 7 (depends on 1)

The component of claim 1, wherein the scrim is impregnated with the thermoplastic matrix.

### Claim 8 (depends on 1)

The component of claim 1, wherein the thermoplastic matrix mixes with the thermoset matrix at the interface.

### Claim 9 (depends on 1)

The component of claim 1, wherein the component is configured as an aircraft component.

### Claim 10 (depends on 1)

The component of claim 1, wherein the thermoplastic matrix consists of the amorphous thermoplastic.

### Claim 11

A component for an aircraft, comprising:
a skin comprising a thermoplastic layer, a thermoset layer and a scrim at an interface between the thermoplastic layer and the thermoset layer;
the thermoplastic layer comprising a plurality of particles within a thermoplastic matrix, and the thermoplastic matrix comprises an amorphous thermoplastic;
the thermoset layer comprising fiber-reinforcement within a thermoset matrix, and the thermoset layer configured to form an exterior flow surface of the component; and
a thermoplastic structural support bonded to the thermoplastic layer, the thermoplastic structural support configured to structurally reinforce the skin.