Methods for manufacturing thermally protected polymer composite structure
AssigneeThe Boeing Company
InventorsJeremy N. O'Hara, Chad D. Belt, Marcos Pantoja, Charles A. Rhodes, James A. Thomas, Evan M. Lloyd
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Abstract
A method for manufacturing a thermally protected polymer composite structure using a thermal barrier layer, the thermal barrier layer being porous and including a tool-side surface and a non-tool-side surface opposed from the tool-side surface, the method including co-bonding an adhesive onto the non-tool-side surface of the thermal barrier layer to yield a coated thermal barrier layer comprising a coated surface, and co-bonding a polymer matrix composite material onto the coated surface of the coated thermal barrier layer.
Claims38
A method for manufacturing a thermally protected polymer composite structure using a thermal barrier layer, the thermal barrier layer being porous and comprising a tool-side surface and a non-tool-side surface opposed from the tool-side surface, the method comprising:
- curing an adhesive onto the non-tool-side surface of the thermal barrier layer to yield a coated thermal barrier layer comprising a coated surface;
- and
- co-bonding a polymer matrix composite material onto the coated surface of the coated thermal barrier layer.
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A method for manufacturing a thermally protected polymer composite structure, the method comprising:
- positioning a thermal barrier material onto a work surface of a tool;
- curing the thermal barrier material on the tool to yield a thermal barrier layer, wherein the thermal barrier layer is porous and comprises a tool-side surface and a non-tool-side surface opposed from the tool-side surface;
- curing an adhesive onto the non-tool-side surface of the thermal barrier layer to yield a coated thermal barrier layer comprising the tool-side surface and a coated surface opposed from the tool-side surface;
- and
- co-bonding a polymer matrix composite material onto the coated surface of the coated thermal barrier layer.
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A method for manufacturing a thermally protected polymer composite structure, the method comprising:
- positioning a thermal barrier material onto a work surface of a tool, wherein the thermal barrier material comprises a thermal barrier reinforcement material and a thermal barrier matrix material, wherein the thermal barrier reinforcement material comprises at least one of glass, carbon, and quartz, wherein the thermal barrier matrix material comprises polyceramic resin;
- curing the thermal barrier material on the tool to yield a thermal barrier layer, wherein the thermal barrier layer is porous and comprises a tool-side surface and a non-tool-side surface opposed from the tool-side surface;
- curing an adhesive onto the non-tool-side surface of the thermal barrier layer at a first adhesive curing hold temperature followed by a second adhesive curing hold temperature to yield a coated thermal barrier layer comprising the tool-side surface and a coated surface opposed from the tool-side surface, wherein the adhesive comprises at least one of polyimide and bismaleimide, wherein the second adhesive curing hold temperature is about at least 20 percent greater than the first adhesive curing hold temperature;
- and
- co-bonding a polymer matrix composite material onto the coated surface of the coated thermal barrier layer, wherein the polymer matrix composite material comprises a reinforcement material and a matrix material.
A thermally protected polymer composite structure comprising:
- a thermal barrier layer, the thermal barrier layer being porous and comprising a tool-side surface and a non-tool-side surface opposed from the tool-side surface;
- an adhesive disposed onto the non-tool-side surface of the thermal barrier layer to yield a coated thermal barrier layer comprising a coated surface;
- and
- a polymer matrix composite material disposed onto the coated surface of the coated thermal barrier layer.
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A method for manufacturing a thermally protected polymer composite structure using a thermal barrier layer, the thermal barrier layer being porous and comprising a tool-side surface and a non-tool-side surface opposed from the tool-side surface, the method comprising:
- scaling the non-tool-side surface of the thermal barrier layer with an adhesive to yield a coated thermal barrier layer comprising a coated surface;
- and
- joining a polymer matrix composite material onto the coated surface of the coated thermal barrier layer.
Dependencies are inferred from the claim text.