# US 7,746,279 B2 · Composite structures with integral intelligent skin

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- Number: US 7,746,279 B2
- Document ID: US7746279B2
- Status: Granted
- Kind: B2
- Application number: 12/419,833
- Filed: 2009-04-07
- Published: 2009-07-30
- Granted: 2010-06-29
- Earliest claimed: 2006-06-07
- Assignees: General Atomics
- Inventors: Thomas R. McGovern; Ronald N. Hubbard
- Web page: https://patentgrep.com/patent/US7746279B2

## CPC

- B29C 70/882: {partly or totally electrically conductive, e.g. for EMI shielding (conductive floors or floor coverings H05F3/025; EMI shielding in general H05K9/00)}
- B29C 70/088: {and with one or more layers of non-plastics material or non-specified material, e.g. supports}
- B29C 70/46: using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B32B 7/00: Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- Y10T 428/31504: Composite [nonstructural laminate]
- 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)
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Composite structures having an integral intelligent skin are made of one or more plies of a structural base material and an intelligent or smart film by molding one or more plies and the film into an integral unitary body with the intelligent film outermost. The intelligent or smart film contains or bears a functionally active or interactive component such as antennae, electronic sensors, electric and/or electronic circuitry, and/or spectrally tailored coatings. A method of making the composite structure in a very economical manner is disclosed.

## Claims

### Claim 1

A method of making a composite structure with an integral intelligent skin comprising the steps of
providing a mold,
providing one or more plies of a structural base material,
providing an intelligent film,
laying the one or more plies and the film in the mold with the film so oriented as to constitute an outer surface of the structure,
molding the one or more plies and the film to form a molded composite structure having an integral intelligent skin, and
removing the composite structure from the mold.

### Claim 2 (depends on 1)

A method as set forth in claim 1 wherein the mold includes an upwardly facing cavity and the one or more plies and the film are laid in the cavity with the film lowermost.

### Claim 3 (depends on 1)

A method as set forth in claim 1 wherein one or more of the plies comprises graphite fibers in a resin matrix.

### Claim 4 (depends on 1)

A method as set forth in claim 1 wherein the film is spectrally tailored.

### Claim 5 (depends on 1)

A method as set forth in claim 1 wherein the film incorporates electric and/or electronic circuitry.

### Claim 6 (depends on 1)

A method as set forth in claim 1 wherein the film incorporates electric and/or electronic sensors.

### Claim 7 (depends on 1)

A method as set forth in claim 1 wherein the film incorporates means for receiving and/or transmitting signals.

### Claim 8 (depends on 1)

A method as set forth in claim 1 wherein the film comprises an antenna.

### Claim 9 (depends on 1)

A method as set forth in claim 1 wherein the film has an active surface and the one or more plies and the film are laid in the mold with the film so oriented that the active surface of the film constitutes the outer surface of the structure.

### Claim 10 (depends on 1)

A method as set forth in claim 1 wherein the molding step is carried out at elevated temperature and reduced pressure.

### Claim 11 (depends on 10)

A method as set forth in claim 10 wherein the molding step is carried out at a temperature of from about 140 to about 150° F. and at a pressure of from about 20 to about 28 ″Hg.

### Claim 12 (depends on 11)

A method as set forth in claim 11 wherein the duration of the molding step is from about 16 to about 24 hours.

### Claim 13

A method of making a composite structure with an integral intelligent skin comprising the steps of
providing a mold,
providing one or more plies of a structural base material,
providing an intelligent film,
laying the one or more plies and the film in the mold with the film so oriented as to constitute an outer surface of the structure,
molding the one or more plies and the film to form a molded composite structure having an integral intelligent skin, and
removing the composite structure from the mold,
wherein the intelligent film incorporates one or more electronic devices.