Integral thermoset/thermoplastic composite joint

Abstract

A prepreg thermoset sheet, ready to be cured, is molded with a preprocessed thermoplastic part to form an integral thermoset/thermoplastic composite joint. The composite produces a more robust access panel. The thermoplastic part is more damage tolerant and easy to repair. The thermoset part, while more difficult to repair, is cheaper than the thermoplastic part and thus used in those places where damage is not likely to occur. The method of molding the two parts together comprises: (a) providing a first part comprising the thermoset resin and a second part comprising the thermoplastic resin, both resins being partially miscible in each other; and (b) forming an interface between the first and second parts by bringing the parts into mutual contact and heating the parts at a temperature and pressure for a period of time sufficient to promote mutual miscibility prior to forming a network structure in the thermoset resin. The integral thermoplastic/thermoset composite joint produced in accordance with the teachings of the present invention is a unique composite joint, produced by interfacing/co-curing two traditionally incompatible materials into a hybrid structural system. The conditions for forming the hybrid structural system derive from the use of thermoplastic materials and thermoset materials that are at least partially miscible in each other at an elevated temperature.

Dependencies are inferred from the claim text.