Molding composite part with metal layer
AssigneeThe Boeing Company
InventorsEric A. Bruton, Christopher H. Childers, Stephen P. Gaydos
Life of this patent
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Abstract
A method of molding a metalized composite part. The method comprises: introducing particles comprising at least one metal into a gas stream; directing the gas stream toward a surface of a thermoplastic composite part, thereby depositing a metal layer on the composite part to form a metallized composite part; and molding the metallized composite part to introduce a bend without delamination of the metal layer from the metallized composite part.
Claims30
A method of molding a metalized composite part, the method comprising:
- introducing particles comprising at least one metal into a gas stream;
- directing the gas stream toward a surface of a thermoplastic composite part, thereby depositing a metal layer on the composite part to form a metallized composite part;
- and
- molding the metallized composite part to introduce a bend without delamination of the metal layer from the metallized composite part.
A method of imparting electrical EMI resistance or lightning protection to a thermoplastic composite part, the method comprising:
- introducing particles comprising at least one metal into a gas stream;
- directing the gas stream toward a surface of a thermoplastic composite part, thereby depositing a metal layer on the composite part to form a metallized composite part;
- and
- molding the metallized composite part to introduce a bend without delamination of the metal layer from the metallized composite part,
- wherein the metal layer imparts electrical EMI resistance or lightning protection to the thermoplastic composite part.
A cold sprayed metal coated article comprising:
- a thermoplastic composite part having at least one surface;
- and
- a cold sprayed metal layer present on the thermoplastic composite part, the cold sprayed metal layer having a deformation produced by molding the thermoplastic composite part together with the cold sprayed metal layer;
- optionally an electrochemical insulating layer disposed between the thermoplastic composite part and the cold sprayed metal layer;
- and
- optionally at least one additional metal layer, the at least one additional metal layer sandwiching at least a portion of the metal layer between the at least one additional metal layer and the thermoplastic composite part;
- the cold sprayed metal coated article having an increase in one or more properties chosen from EMI resistance, erosion protection, lightning protection, electromagnetic interference shielding, electromagnetic emission shielding and lightning strike protection compared to the same thermoplastic composite part without the cold sprayed metal layer.
Dependencies are inferred from the claim text.