HYBRID PLATED COMPOSITE STACK |
|||||||
申请号 | US14903908 | 申请日 | 2014-07-09 | 公开(公告)号 | US20160152005A1 | 公开(公告)日 | 2016-06-02 |
申请人 | UNITED TECHNOLOGIES CORPORATION; | 发明人 | James T. ROACH; Grant O. COOK; | ||||
摘要 | A composite laminate component is disclosed. The composite laminate component may comprise a composite laminate including a plurality of sub-laminates, and a metallic layer encapsulating one or more of the sub-laminates. The sub-laminates may be joined by a bond between the metallic layers. | ||||||
权利要求 | What is claimed is: |
||||||
说明书全文 | This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Serial Number 61/844,108 filed on Jul. 9, 2013. The present disclosure generally relates to composite laminate components. More specifically, this disclosure relates to composite laminate components plated with metallic layers. Composite laminates are attractive materials for numerous applications and consist of high-strength layers of fabric (or lamina) embedded in a polymeric, ceramic, or metal matrix. Composite laminates formed in a polymer matrix may be referred to as polymer matrix composites (PMCs), those formed in a ceramic matrix may be referred to as ceramic matrix composites (CMCs), and those formed in a metal matrix may be referred to as metal matrix composite (MMCs). The high-strength lamina may be formed from woven fibers of carbon, glass, aramid, boron, or any other high-strength fiber. Although composite laminates are associated with high in-plane stiffness (i.e., in the plane of the fabric layer), the weak interfacial strength between the lamina and their consequent tendency towards de-lamination (i.e., the pulling apart of individual lamina in the laminate) has precluded the use of these materials in some applications. In addition, the outer-most lamina may be more subject to a wide array of environmental effects such as ultraviolet (UV) damage, erosion, and handling damage. Clearly, there is a need for systems which improve the resistance of composite laminates towards delamination as well as the structural resilience of composite laminates as a whole. In accordance with one aspect of the present disclosure, a composite laminate component is disclosed. The composite laminate component may comprise a composite laminate, and a metallic layer applied to at least one surface of the composite laminate. In another refinement, the composite laminate may be a polymer matrix composite. In another refinement, the composite laminate may be a metal matrix composite. In another refinement, the composite laminate may be a ceramic matrix composite. In another refinement, the metallic layer may encapsulate the composite laminate. In another refinement, the composite laminate may include a plurality of sub-laminates, and the metallic layer may be applied at an interface between at least two of the sub-laminates. In another refinement, the composite laminate may include a plurality of sub-laminates, and the metallic layer may be applied to a surface of each of the sub-laminates that lies at an interface with another sub-laminate. In another refinement, the metallic layers at the interface between the sub-laminates may be joined by bonds. In another refinement, the composite laminate may include a plurality of sub-laminates, and a metallic layer may encapsulate each of the sub-laminates. In another refinement, the metallic layers encapsulating the sub-laminates may be joined by bonds. In another refinement, the composite laminate component may be further encapsulated in a metallic layer. In another refinement, the composite laminate component may be further encapsulated in a polymeric material. In accordance with another aspect of the present disclosure, a composite laminate component is disclosed. The composite laminate component may comprise a composite laminate including a plurality of sub-laminates, and a metallic layer encapsulating at least one of the sub-laminates. In another refinement, a metallic layer may encapsulate each of the sub-laminates. In another refinement, the sub-laminates may be joined by bonds between the metallic layers. In another refinement, the bonds may be formed by transient liquid phase bonding. In another refinement, the bonds may be formed by adhesive bonding. In accordance with another aspect of the present disclosure, a method for fabricating a composite laminate component is disclosed. The method may comprise: 1) providing a plurality of sub-laminates, 2) applying a metallic layer to a surface of at least one of the sub-laminates, 3) stacking the sub-laminates, and 4) joining the sub-laminates to provide the composite laminate component. In another refinement, applying a metallic layer to a surface of at least one of the sub-laminates may comprise encapsulating each of the sub-laminates in a metallic layer. In another refinement, joining the sub-laminates may comprise forming bonds between the metallic layers by transient liquid phase bonding or adhesive bonding. These and other aspects and features of the present disclosure will be more readily understood when read in conjunction with the accompanying drawings. It should be understood that the drawings are not necessarily drawn to scale and that the disclosed embodiments are sometimes illustrated schematically and in partial views. It is to be further appreciated that the following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses thereof. In this regard, it is to be additionally appreciated that the described embodiment is not limited to use with certain applications. Hence, although the present disclosure is, for convenience of explanation, depicted and described as certain illustrative embodiments, it will be appreciated that it can be implemented in various other types of embodiments and in various other systems and environments. Referring now to Each of the lamina 366 may consist of a woven fabric layer of reinforcing fibers such as, but not limited to, carbon, glass, aramid, or boron fibers which provide the lamina 366 with high strength in the plane of the fabric layers. In addition, each of the woven fabric layers may have different thicknesses, different orientations with respect to one another, and different material compositions. The lamina 366 may be embedded in a matrix of polymer, ceramic, or metal to adhesively bind the lamina 366 together to form a PMC, a CMC, or an MMC, respectively. If the matrix is formed from a polymer, it may consist of one or more thermoplastic or thermoset materials. Suitable thermoplastic materials for the polymer matrix may include, but are not limited to, polyetherimide (PEI), thermoplastic polyimide, polyether ether ketone (PEEK), polyether ketone ketone (PEKK), polysulfone, polyamide, polyphenylene sulfide, polyester, polyimide, combinations thereof, or any of the foregoing with optional reinforcement with carbon or glass fiber. Suitable thermoset materials may include, but are not limited to, condensations polyimides, addition polyimides, epoxy cured with aliphatic and/or aromatic amines and/or anhydrides, cyanate esters, phenolics, polyesters, polybenzoxazine, polyurethanes, polyacrylates, polymethacrylates, silcones (thermoset), or any of the foregoing with optional reinforcement with carbon or glass fibers. The metallic layer 364 may consist of any platable material such as, but not limited to, nickel, cobalt, copper, iron, gold, silver, palladium, chromium, zinc, tin, cadmium, and alloys with any of the foregoing elements comprising at least 50 wt. % of the alloy, or combinations thereof. As an alternative arrangement, a hybrid composite laminate component 370 having one or more metallic layers 364 between the sub-laminates 368 is shown in To form the component 370, the sub-laminates 368 (plated and non-plated) may be assembled in a stack and joined to form a unitary structure using a conventional composite fabrication technique such as, but not limited to, compression molding and resin transfer molding. Alternatively, metallic layers 364 at the interface of the sub-laminates 368 (or at the interface of the lamina 366) may be joined to form a bond 372 at the interface of the sub-laminates 368 (or at the interface of the laminae 366), as shown in As shown in A series of steps which may be performed for the fabrication of the hybrid composite laminate components of the present disclosure are depicted in Selected sub-laminates 368 may also be encapsulated in a metallic layer according to a block 385 (see Following the block 389, the formed hybrid composite components (e.g., components 370 and 375) may be optionally encapsulated in a metallic layer 364 according to a block 395 (see Alternatively, the composite laminate 362 (see It is further noted that segments of composite laminate structures and/or hybrid composite laminate structures may be formed and later joined to form a unitary structure by encapsulation in a metallic layer and/or by joining metallic layers by conventional processes such as TLP bonding, adhesive bonding, or various welding processes (e.g., ultrasonic, friction, friction-stir). In this way, components having complex structures and/or mounting features may be accessed by joining segments having simpler structures. From the foregoing, it can therefore be seen that the present disclosure can find industrial applicability in many situations, including, but not limited to, industries requiring light-weight and high-strength composite laminate components having improved resistance against delamination. The technology as disclosed herein provides composite laminate components and/or sub-laminates encapsulated in one or more metallic layers to increase the strength of the component, resist delamination, and improve the resistance of the component against environmental effects such as fire, erosion, or foreign-object damage. Furthermore, as disclosed herein, metallic layers may be introduced on the surface of selected laminae and/or sub-laminates to provide delamination-resistant hybrid composite structures having metallic layers at the interface of laminae and/or sub-laminates. In addition, selective thickening of the metallic layers may be exploited to optimize surface properties such as fire resistance, erosion resistance, and delamination resistance in selected areas without adding undue weight to the part. The technology as disclosed herein may find wide industrial applicability in a wide range of areas including, but not limited to, aerospace, automotive, and sporting industries. |