The Boeing Company

Commonwealth Scientific and Industrial Research Organisation

Lumimove, Inc.

Jost Chemical Company

Eric Alan Bruton

Patrick John Kinlen

Matthew Alexander Flack

Andrew M Zweig

Stephen P Gaydos

Christian Hornung

Kenneth Walter Young

John Tsanaktsidis

Thomas Kohl

Loyal Bruce Shawgo

Christopher Harold Childers

Edward W Brouwers

John F Gleason

Douglas Jost

Douglas Caskey

Shane Haley

Mauricio Pinto

Rebecca A Callahan

Teresa Bandrowsky

Richard J Toth

John Gleason

Matthew A Flack

The present disclosure relates to a cold spray metal process for providing an electrical connection within a multilayered composite article. The present disclosure relates to a cold sprayed metal coated article or a structural component having a polymeric composite material having at least one surface, a thermoplastic electrochemical insulating layer on the at least one surface, an electrical circuit may include a cold sprayed metal coating present on at least a portion of a surface of the electrochemical insulating layer, and at least one additional layer, the at least one additional layer encapsulating at least a portion of the cold sprayed metal between the additional layer and the electrochemical insulating layer. The structural component may include a cold sprayed metal coating having one or more non-continuous segments, where the one or more non-continuous segments are not in lateral contact with one another.

Cold sprayed electrical circuits and methods thereof

A filter comprises a support substrate. A film is disposed on the support substrate, the film comprising a polymer matrix material and a filler. The filler has a particle size distribution configured to filter a desired range of wavelengths of light, the particle size distribution having been achieved by extrusion. An extrudable composition is also disclosed. The extrudable composition comprises a polymer matrix material and a filler. The filler has an average particle size ranging from about 1 nm to about 700 nm and a concentration ranging from 0.001 weight % to 0.3 weight %, relative to the total weight of the extrudable composition.

Extrudable compositions comprising fillers and devices made from the compositions

The present disclosure relates to a continuous flow process for preparing conducting polymers, for example polyaniline. The continuous flow process can provide a controlled synthesis of a conducting polymer from an emulsion comprising a polymerizable organic monomer and a free radical initiator in flow within a temperature controlled continuous flow reactor comprising at least one mixing element. The present disclosure also relates to the conducting polymers prepared by the continuous flow process.

Continuous flow process for preparing conducting polymers

The present disclosure relates to a cold spray metal process for imparting electromagnetic interference (EMI) resistance or lightning protection to the surface of a polymer, and a polymer with surface EMI resistance, or lightning protection, articles coated therefrom, and methods of reducing or eliminating electrochemical interactions between the metallic coating and components of the polymer.

Cold spray metallic coating and methods

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

The present disclosure provides polyanilines, articles thereof, and methods of forming polyanilines. In at least one aspect, a polyaniline has a thermal stability of about 100° C. or greater, a weight average molecular weight (Mw) of from about 50,000 g/mol to about 150,000 g/mol and a molecular weight distribution (Mw/Mn) of from about 1 to about 5. In at least one aspect, a film includes a polyaniline, the film having a hydrocarbon content of about 1 wt % or less, based on the total weight of the film. In at least one aspect, a method includes introducing an emulsion of an aqueous solution of an aniline and an alkyl-substituted aryl sulfonic acid having 1 wt % or less of hydrocarbon content into a flow reactor, the flow reactor having a length of tubing having an inner diameter. The method includes polymerizing the monomer within the tube to form a polyaniline.

Polyanilines 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

The present disclosure provides polyanilines, articles thereof, and methods of forming polyanilines. In at least one aspect, a polyaniline has a thermal stability of about 100&#xb0; C. or greater, a weight average molecular weight (Mw) of from about 50,000 g/mol to about 150,000 g/mol and a molecular weight distribution (Mw/Mn) of from about 1 to about 5. In at least one aspect, a film includes a polyaniline, the film having a hydrocarbon content of about 1 wt % or less, based on the total weight of the film. In at least one aspect, a method includes introducing an emulsion of an aqueous solution of an aniline and an alkyl-substituted aryl sulfonic acid having 1 wt % or less of hydrocarbon content into a flow reactor, the flow reactor having a length of tubing having an inner diameter. The method includes polymerizing the monomer within the tube to form a polyaniline.

An example method includes: forming a conductive layer on at least a portion of a surface of a substrate, where the substrate comprises a composite material of an aerodynamic structure, and where the conductive layer is configured to provide a conductive path to conduct an electric current generated by a lightning strike to an electrically-grounded location; depositing an insulating layer on the conductive layer; removing one or more portions of the insulating layer to form respective gaps in the insulating layer and expose corresponding one or more portions of the conductive layer; and forming a resistive-heater layer on the insulating layer such that the resistive-heater layer fills the respective gaps in the insulating layer and contacts the corresponding one or more portions of the conductive layer, such that when electric power is provided to the conductive layer, the electric power is communicated to the resistive-heater layer thereby generating heat therefrom.

Integrated lightning protection and electrical de-icing for aerodynamic structures

A method of controlling a particle size distribution of a filler in an extrudable composition comprises introducing an extrudable composition comprising a polymer matrix material and a filler into an extruder, the filler having a first average particle size that is larger than a target average particle size. The extrudable composition is extruded one or more times using the extruder to reduce the size of the filler from the first average particle size to a reduced average particle size, the reduced average particle size being within 10% of the target average particle size.

Method of controlling particles size of fillers in extrudable compositions, compositions comprising the fillers and devices made from the compositions

A protective coating composition for providing protection to a component of a ram air turbine system in need thereof. The protective coating composition comprises an aqueous-soluble or alkaline-soluble polymer matrix, one or more compressible fillers, and one or more non-compressible fillers. The disclosure also provides a method for providing a protective coating onto components of a ram air turbine system in need thereof for providing indentation and scratch resistance thereto.

Growing community of inventors

St. Louis, MO, United States of America

Eric Alan Bruton