The Boeing Company

Christopher Harold Childers

Gregg Robert Bogucki

Stephen R Heinz

Christopher S Steinman

Eric Alan Bruton

Cori A Jackson

Stephen P Gaydos

Charles Richard Prebil

Kenneth Walter Young

Jason Turner

Michael John Cloud

Nicholas Sondker

A multilayered article is disclosed, the multilayered article including a thermosetting polymer material having at least one surface, a thermoplastic polymer layer deposited on the at least one surface of the thermosetting polymer material, a cold sprayed metal layer present on at least a portion of a surface of the thermoplastic polymer layer, at least one additional layer, the at least one additional layer sandwiching at least a portion of the cold sprayed metal layer between the additional layer and the thermoplastic polymer layer, where the thermoplastic polymer layer has a crystallinity of about 5% to about 60%. A method of providing a composite laminate structure is also disclosed.

Composite laminates with metal layers and methods thereof

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.

Molding composite part with metal layer

A composite laminate structure includes a cellular core and a first laminate layer coupled to the cellular core. The first laminate layer includes a first thermoplastic layer and a first fiber-reinforced polymer layer, where a first surface of the first fiber-reinforced polymer layer is thermally consolidated to a second surface of the first thermoplastic layer. A first surface of the first thermoplastic layer is directly in contact with and bound to a first surface of the cellular core by temperature reduction of the first thermoplastic layer below a glass transition temperature of the first thermoplastic layer while the cellular core is pressed against the first thermoplastic layer when the first thermoplastic layer is above the glass transition temperature of the first thermoplastic layer and the cellular core is below a temperature where materials of the cellular core flow or degrade.

Composite laminate structure having a cellular core formed using a continuous compression molding process

Aspects of the present disclosure generally describe polyarylether ketones and methods of use. In some aspects, a composition includes one or more polymers of formula (IV): 

Polyarylether ketone imide adhesives

A method for continuously fabricating a composite sandwich structure includes the steps of: (1) preheating a laminate to a preforming temperature above a glass transition temperature of the laminate but below or equal to a crystalline melt temperature of the laminate as the laminate is substantially continuously moved through a preheating zone, wherein the laminate comprises a first face sheet, a second face sheet and a core sandwiched between the first face sheet and the second face sheet; (2) consolidating the laminate as the laminate is substantially continuously moved through a consolidation zone in line with the preheating zone to form a continuous length of the composite sandwich structure; (3) moving the composite sandwich structure, substantially continuously, through at least one of a texturing zone and a coating zone; and (4) incrementally applying at least one of a surface texture and a surface coating to at least one surface of the composite sandwich structure.

Method and apparatus for continuously fabricating a composite sandwich structure

A method for continuously fabricating a composite sandwich structure includes the steps of: (1) moving a laminate, substantially continuously, through a preheating zone, wherein the laminate includes a first face sheet, a second face sheet and a core sandwiched between the first face sheet and the second face sheet; (2) preheating the laminate to a preforming temperature above a glass transition temperature of the laminate and below or equal to a crystalline melt temperature of the laminate as the laminate is being moved through the preheating zone; (3) moving the laminate, substantially continuously, through a consolidation zone; and (4) consolidating the laminate as the laminate is being moved through the consolidation zone to form a continuous length of the composite sandwich structure.

Aspects of the present disclosure generally describe polyarylether ketones and methods of use. In some aspects, a composition includes one or more polymers of formulae (I), (II), or (III): 

Growing community of inventors

St. Charles, MO, United States of America

Christopher Harold Childers