Methods of making laminate structures

A method of making a laminate structure, the method comprising:

• laying up a first layer on a mold tool, wherein the first layer comprises one of an aluminum layer and a carbon composite layer;
• laying up a glass composite layer on the first layer;
• laying up an adhesive layer on the glass composite layer;
• laying up a second layer on the adhesive layer, wherein the second layer comprises the other one of the aluminum layer and the carbon composite layer;
• and
• consolidating one or more thermoplastic prepreg plies of the glass composite layer and one or more thermoplastic prepreg plies of the carbon composite layer;
• wherein the first layer, the glass composite layer, the adhesive layer, and the second layer form a stack,
• wherein the glass composite layer prevents interaction between the aluminum layer and the carbon composite layer, and
• wherein the consolidating of the one or more thermoplastic prepreg plies of the glass composite layer and the one or more thermoplastic prepreg plies of the carbon composite layer comprises:
• raising a temperature of the stack to greater than or equal to 600° F.;
• raising a pressure of the stack to greater than or equal to 50 pounds per square inch gage (psig);
• and
• holding the temperature and pressure of the stack for greater than or equal to 5 minutes and less than or equal to 15 minutes, and
• wherein the consolidating of the one or more thermoplastic prepreg plies of the glass composite layer and the one or more thermoplastic prepreg plies of the carbon composite layer comprises a heat-up phase wherein the pressure is low and the heat up rate is any value, a hold phase wherein the temperature is held to greater than or equal to 600° F. and the pressure is held to greater than or equal to 50 psig for greater than or equal to 5 minutes, and a cooldown phase wherein a temperature cooldown rate is limited and a pressure band is maintained until the temperature is significantly reduced.

A method of making a laminate structure, the method comprising:

• laying up a first layer on a mold tool, wherein the first layer comprises one of an aluminum layer and a carbon composite layer;
• laying up a lower adhesive layer on the first layer;
• laying up a glass composite layer on the lower adhesive layer;
• laying up an upper adhesive layer on the glass composite layer;
• laying up a second layer on the upper adhesive layer, wherein the second layer comprises the other one of the aluminum layer and the carbon composite layer;
• and
• consolidating one or more thermoplastic prepreg plies of the glass composite layer and one or more thermoplastic prepreg plies of the carbon composite layer;
• wherein the first layer, the lower adhesive layer, the glass composite layer, the upper adhesive layer, and the second layer form a stack,
• wherein the glass composite layer prevents interaction between the aluminum layer and the carbon composite layer, and
• wherein the consolidating of the one or more thermoplastic prepreg plies of the glass composite layer and the one or more thermoplastic prepreg plies of the carbon composite layer comprises:
• raising a temperature of the stack to greater than or equal to 600° F.;
• raising a pressure of the stack to greater than or equal to 50 pounds per square inch gage (psig);
• and
• holding the temperature and pressure of the stack for greater than or equal to 5 minutes and less than or equal to 15 minutes, and
• wherein the consolidating of the one or more thermoplastic prepreg plies of the glass composite layer and the one or more thermoplastic prepreg plies of the carbon composite layer comprises a heat-up phase wherein the pressure is low and the heat up rate is any value, a hold phase wherein the temperature is held to greater than or equal to 600° F. and the pressure is held to greater than or equal to 50 psig for greater than or equal to 5 minutes, and a cooldown phase wherein a temperature cooldown rate is limited and a pressure band is maintained until the temperature is significantly reduced.