molybdenum composite hybrid laminate and method of forming a molybdenum composite hybrid laminate

专利摘要:
MOLYBDENUM COMPOSITE HYBRID LAMINATES AND METHODS. The present invention relates to a hybrid molybdenum composite laminate. The laminate has a plurality of layers of composite material. The laminate also has a plurality of surface-treated molybdenum sheet layers interlaced between the layers of composite material. The laminate further has a plurality of adhesive layers disposed between and connecting adjacent layers of the layers of composite material and the layers of molybdenum sheet.
公开号:BR112014002438B1
申请号:R112014002438-3
申请日:2012-06-27
公开日:2020-07-28
发明作者:Marc R. Matsen；Mark A. Negley；Marc J. Piehl；Kay Y. Blohowiak；Alan Edgar Landmann；Richard H. Bossi；Robert L. Carlsen；Gregory Alan Foltz；Geoffrey A. Butler；Liam S. Cavanaugh Pingree；Stephen G. Moore；John Mark Gardner；Robert A. Anderson
申请人:The Boeing Company；
IPC主号:

专利说明:

BACKGROUND 1) DESCRIPTION FIELD
[001] The invention relates to composite materials and methods and, more particularly, to hybrid composite laminates and methods for use in composite structures, such as aircraft, spacecraft and other vehicles. 2) DESCRIPTION OF RELATED TECHNIQUE
[002] Composite structures and component parts are used in a wide variety of applications, including the manufacture of aircraft, spacecraft, helicopter, vessel, automobiles, trucks and other vehicles. In particular, in aircraft construction, composite structures and component parts are used in increasing amounts to form the fuselage, wings, tail section, aircraft cover panels and other component parts of the aircraft.
[003] There are known methods for making hybrid laminates that combine polymeric composite materials, such as graphite, boron, or a blend of graphite and composite boron and sheet metal materials, such as titanium. The sheet metal material can be added between seated substrates of polymeric composite unidirectional tape. For example, U.S. Patent No. 5,866,272 to Westre et al., Is one of several relatives that teach the positioning of titanium foil between polymeric composite unidirectional tape substrates.
[004] However, the known hybrid laminate and composite materials can only leverage the strengthening of the fibers that are in the card path and not leverage the strength of the fibers outside the geometric axis. In addition, known composite and hybrid laminate materials may not be effective in providing a current dissipation path in the composite structure, for example, for protection against effective lightning strike. In addition, known hybrid and composite laminate materials may not provide sufficient impact resistance from high impact sources, such as hail or bird collisions, without having to change the structure by cross-stitching or increasing the thickness of the composite structure, to name a few methods. In addition, known composite and hybrid laminate materials may not provide effective thermal shock resistance from high energy thermal shock sources, such as lasers and X-rays. In addition, known composite and hybrid laminate materials may not provide the ability to combine separate electrical and structural systems into a single system on an aircraft.
[005] In addition, lightweight composite designs, such as for aircraft keel beams, may require additional structurally parasitic conductors to effectively disperse current from a lightning strike. These additional drivers can add weight to the aircraft and can result in overhead costs and increased fuel costs. Known composite and hybrid laminate materials may not provide the desired lightness, high-performance composite keel beam that can be effective in conducting current and acting as a lightning current return path.
[006] Additionally, when system penetrations, access paths and other non-load bearing areas are required in hybrid or composite composite structures or panels, it may be necessary to pad the settlement to facilitate the transmission of cargo around these areas. Known composite and hybrid laminate materials can be used to provide extra thickness which can result in weight, part volume and additional cost to the composite structure.
[007] Furthermore, temperature and thermal uniformity and the ability to control excessive thermal energy due to the curing kinetics of resins are important manufacturing problems when curing thermoset composites. Temperature and thermal control of the curing cycle can prevent the use of some composite configurations.
[008] Additionally, the repair areas of the composite structures may need a significant increase in the thickness of the composite structure to restore the composite structure to at least its original strength. This can cause additional aerodynamic drag and can also affect the appearance of the composite structure.
[009] Additionally, the manufacture of composite parts lasts, the substrates of an uncured composite part that has a uniform cross-section can crinkle in one or more areas where a pre-cured or cured composite part that has a cross-section non-uniform is joined to the uncured composite part. This wrinkling of the substrates can happen due to differences in pressure between the pre-cured or cured composite part and the uncured composite part in the joined areas. This wrinkling of the substrates can result in fiber distortion of the composite material in the uncured composite part.
[0010] Finally, determining the initiation and propagation of faults in composite structures is important in predicting the useful life and maintenance of the composite structure. Known composite and hybrid laminate structures are typically replaced or repaired at certain intervals. These intervals are by their conservative nature, which can lead to the addition of potentially unnecessary additional cost.
[0011] Consequently, there is a need in the art for hybrid composite laminates and methods that provide advantages over known composite materials and hybrid composite laminates and known methods. SUMMARY
[0012] This need for hybrid composite laminates and methods is satisfied. As discussed in the detailed description below, the modalities of hybrid molybdenum composite laminates and methods can provide significant advantages over existing laminated materials, methods and systems.
[0013] In one embodiment of the description, a composite molybdenum hybrid laminate is provided. The laminate comprises a plurality of layers of composite material. The laminate further comprises a plurality of surface treated molybdenum sheet layers interlaced between the layers of composite material. The laminate further comprises a plurality of adhesive layers disposed between and joining the adjacent layers of the composite material layers and the molybdenum sheet layers.
[0014] In another embodiment of the description, a molybdenum laminate seat is provided. The laying of molybdenum laminate comprises a plurality of layers of composite material. The laying of molybdenum laminate further comprises a plurality of layers containing molybdenum sheet interlaced between the layers of composite material. Each layer containing molybdenum sheet comprises a layer of composite material that has a cut-out portion of a surface-treated molybdenum sheet. The laying of molybdenum laminate further comprises a plurality of adhesive layers disposed between and joining adjacent layers of layers of composite material and layers containing molybdenum sheet.
[0015] In another embodiment of the description, a method of forming a hybrid molybdenum composite laminate is provided. The method comprises treating one surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit.
[0016] In another embodiment of the description, a system is provided to monitor the structural health of a composite structure. The system comprises a composite structure comprising one or more hybrid molybdenum composite laminates. Each laminate comprises a plurality of layers of composite material. The laminate further comprises a plurality of surface treated molybdenum sheet layers interlaced between the layers of composite material. The laminate further comprises a plurality of adhesive layers disposed between and joining the adjacent layers of the layers of composite material and the layers of molybdenum sheet. The system further comprises one or more electrical sensor devices coupled to one or more laminates. The sensor devices guide the electrical current through the layers of molybdenum sheet and monitor any changes in the flow of electrical current through the layers of molybdenum in order to obtain structural health data of the composite structure by means of one or more signals a from one or more electrical sensor devices.
[0017] In another embodiment of the description, a method is provided to monitor the structural health of a composite structure using layers of molybdenum sheet. The method comprises treating one surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method further comprises coupling one or more electrical sensor devices to one or more laminates. The method further comprises directing the electrical current through the layers of molybdenum sheet with one or more electrical sensor devices. The method further comprises monitoring any change in the flow of electrical current through the layers of molybdenum sheet with one or more electrical sensor devices. The method further comprises obtaining the structural health data of the composite structure by means of one or more signals from one or more electrical sensor devices.
[0018] In another modality, a method of fabricating an electric bus in an aircraft structure using layers of molybdenum sheet is provided. The method comprises treating a surface of one of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers acting as an electric bus. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method additionally comprises manufacturing the electric bus of the hybrid molybdenum composite laminate in an aircraft structure.
[0019] In another modality, a method of fabrication in an aircraft structure is provided with an aircraft composite keel beam to disperse electrical current from a lightning strike, the method using layers of molybdenum sheet. The method comprises treating one surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being an aircraft composite keel beam and current return path that disperses electrical current of a lightning strike for an aircraft structure. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method further comprises using the composite molybdenum hybrid laminate in the aircraft structure to disperse electrical current from the lightning strike to the aircraft structure.
[0020] In another modality, a method of improving the radius attenuation of a composite structure with the use of layers of molybdenum sheet is provided. The method comprises treating the surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, with the molybdenum sheet layers being electrical energy dissipation trajectories that enhance a radius attenuation of a composite structure. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method additionally comprises using the composite hybrid molybdenum laminate in the composite structure to improve a radius attenuation of the composite structure.
[0021] In another modality, a method is provided to improve the thermal shock resistance of a composite structure using molybdenum sheet layers. The method comprises treating the surface of each of a plurality of layers of molybdenum sheet. The method additionally comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, with the molybdenum sheet layers being thermal penetration barriers and thermal energy dissipation paths that enhance thermal shock resistance. of a composite structure. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method additionally includes the use of the composite molybdenum hybrid laminate in the composite structure to improve the thermal shock resistance of the composite structure.
[0022] In another modality, a method of improving a curing cycle of a composite structure using the layers of molybdenum sheet is provided. The method comprises treating one surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being thermal and temperature controllers that enhance a curing cycle of a composite structure. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method additionally comprises using the composite molybdenum hybrid laminate in the composite structure to improve the curing cycle of the composite structure.
[0023] In another modality, a method for improving the impact durability of a composite structure using the layers of molybdenum sheet is provided. The method comprises treating the surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being load dissipating paths that enhance the impact durability of a composite structure. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method further comprises using the composite molybdenum hybrid laminate in the composite structure to improve the impact durability of the composite structure.
[0024] In another modality, a method of directing the load around the non-load bearing areas in a composite structure using the layers of molybdenum sheet is provided. The method comprises treating the surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, with the molybdenum sheet layers being load-routing paths that direct load around non-load bearing areas in a composite structure. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method additionally comprises using the hybrid molybdenum composite laminate in the composite structure to direct load around the non-load bearing areas in the composite structure.
[0025] In another modality, a method of reinforcing and extracting cargo is provided away from a repair area in a composite structure using the layers of molybdenum sheet. The method comprises treating the surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being reinforcing elements and load extraction paths that reinforce and extract the load away from a repair area in a composite structure. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method further comprises using the composite molybdenum hybrid laminate in the composite structure to reinforce and extract the load away from the repair area in the composite structure.
[0026] In another modality, a method of smoothing fiber distortion in a composite structure using the layers of molybdenum sheet is provided. The method comprises treating the surface of each of a plurality of layers of molybdenum sheet. The method further comprises interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being fiber stabilizers that soften fiber distortion in a composite structure. The method further comprises bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the conventional improved strength limit. The method further comprises using the hybrid molybdenum composite laminate in the composite structure to smooth the fiber distortion in the composite structure.
In short, according to one aspect of the invention, a hybrid molybdenum composite laminate is provided which includes a plurality of layers of composite material; a plurality of surface-treated molybdenum sheet layers interlaced between the layers of composite material; and a plurality of adhesive layers disposed between and connecting the adjacent layers of the composite material layers and the molybdenum sheet layers.
[0028] Advantageously, the laminate comprises the layer of composite material which comprises a fiber-reinforced polymeric material.
[0029] Advantageously, the laminate comprises the surface-treated molybdenum sheet layer that has sufficient stiffness to leverage a fiber tensile strength and a fiber stiffness outside the geometric axis in the adjacent composite material layers by means of the Poisson effects on the molybdenum sheet layer.
[0030] Advantageously, the laminate comprises the laminate that is used in a composite structure and improves the conventional limit of elasticity in the composite structure.
[0031] Advantageously, the laminate comprises the composite structure which comprises a composite aircraft structure.
[0032] Advantageously, the laminate comprises layers of molybdenum foil that have sufficient strength, sufficient rigidity and sufficient electrical conductivity to enable the layers of molybdenum foil to act as an aircraft keel beam and a return path current to disperse electrical current from a lightning strike to the composite aircraft structure.
[0033] Advantageously, the laminate comprises the layer of molybdenum sheet which has a surface treated to improve the connection between the layer of molybdenum sheet and a layer of adjacent composite material.
[0034] Advantageously, the laminate comprises the layer of molybdenum sheet that has surface treated by means of one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, blasting abrasive, sanding, sandblasting, solvent scrubbing, abrasion, chemical cleaning, laser ablation and chemical corrosion engraving.
[0035] Advantageously, the laminate comprises each of two or more of the layers of material that have a surface-treated molybdenum sheet cutout portion and the cutout portions have internal edges that are staggered to prevent overlapping of two or more inner edges to provide improved load distribution.
[0036] Advantageously, the laminate comprises layers of molybdenum foil that have sufficient electrical conductivity to enable the layers of molybdenum foil to act as an electrical bus for a composite aircraft structure.
[0037] Advantageously, the laminate comprises the laminate that is coupled to one or more electrical sensor devices that guide electrical current through the layers of molybdenum sheet and that monitor any changes in the flow of electrical current through the layers of molybdenum sheet to in order to obtain structural health data from a composite structure.
[0038] Advantageously, the laminate comprises layers of molybdenum foil that have sufficient electrical conductivity and sufficient thermal conductivity to enable the layers of molybdenum foil to act as electrical energy dissipation trajectories that enhance a radius attenuation of a radius. composite structure.
[0039] Advantageously, the laminate comprises layers of molybdenum foil that have a sufficient melting point and sufficient thermal conductivity that enables layers of molybdenum foil to act as thermal penetration barriers and thermal energy dissipation paths that enhance the thermal shock resistance of a composite structure.
[0040] Advantageously, the laminate comprises layers of molybdenum foil that have sufficient thermal conductivity to enable the layers of molybdenum foil to act as thermal and temperature controllers that enhance a curing cycle of a composite structure.
[0041] Advantageously, the laminate comprises layers of molybdenum foil that have sufficient stiffness and sufficient strength to enable the layers of molybdenum foil to act as load dissipation paths that enhance the impact durability of a composite structure.
[0042] Advantageously, the laminate comprises layers of molybdenum foil that have sufficient stiffness and sufficient strength to enable the layers of molybdenum foil to act as load routing paths that direct load around non-load bearing areas. in a composite structure.
[0043] Advantageously, the laminate comprises layers of molybdenum sheet that have sufficient stiffness and sufficient strength to enable the layers of molybdenum sheet to act as reinforcing elements and load extraction paths to reinforce and extract load away. of a repair area in a composite structure.
[0044] Advantageously, the laminate comprises layers of molybdenum foil that have sufficient stiffness and sufficient strength to enable the layers of molybdenum foil to act as fiber stabilizers that mitigate fiber distortion in a composite structure.
[0045] According to another aspect of the invention, a molybdenum laminate seat is provided which includes a plurality of layers of composite material; a plurality of layers containing molybdenum sheet interleaved between the layers of composite material, each layer containing molybdenum sheet comprising a layer of composite material having a cut-out portion of a surface-treated molybdenum sheet; and a plurality of adhesive layers disposed between and connecting adjacent layers of layers of composite material and layers containing molybdenum sheet.
[0046] Advantageously, the laminate in which a plurality of layers containing molybdenum sheet has cut-out portions with internal edges that are staggered to avoid overlapping of two or more inner edges in order to provide an improved load distribution by the molybdenum sheet.
[0047] Advantageously, the laminate additionally comprises one or more layers of surface-treated molybdenum sheet adjacent to one or more of the layers of composite material and layers containing molybdenum sheet.
[0048] Advantageously, the laminate in which no layer of adjacent composite material and layer containing molybdenum sheet is oriented at the same angle.
[0049] In accordance with a further aspect of the present invention, a method of forming a hybrid molybdenum composite laminate is provided, the method including treating one surface of each of a plurality of layers of molybdenum sheet; interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material; and bonding with an adhesive layer each of the surface molybdenum sheet layers treated to the adjacent composite material layers to form a hybrid molybdenum composite laminate that has the conventionally improved elasticity limit.
[0050] Advantageously, the method further comprises using the composite hybrid molybdenum laminate in a composite structure.
[0051] Advantageously, the method additionally comprises, after using the laminate in a composite structure, coupling the laminate to one or more electrical sensor devices in order to guide the electric current through the layers of molybdenum sheet, monitoring any changes in the flow of the electrical current through the layers of molybdenum sheet and obtain data on structural health of the composite structure.
[0052] Advantageously, the method comprises the surface-treated molybdenum sheet layer that has sufficient stiffness to leverage a fiber tensile strength and a fiber stiffness of the fibers outside the geometrical layer on adjacent composite material layers by means of the Poisson effects on the molybdenum sheet layer.
[0053] Advantageously, the method in which the interlacing and bonding further comprise one or more of compacting, consolidating and curing the layers of surface-treated molybdenum sheet and interlaced composite material layers.
[0054] Advantageously, the method comprises treating the surface of the molybdenum sheet layers which comprises one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and etching by chemical corrosion.
[0055] Advantageously, the method comprises each of two or more of the layers of composite material having a surface-treated molybdenum sheet cutout portion and the method further comprises staggering the inner edges of the cutout portions to prevent overlapping of two or more inner edges to provide an improved charge distribution by the molybdenum sheet.
[0056] Advantageously, the method comprises the composite material layer comprising a fiber-reinforced polymeric material.
[0057] Advantageously, the method comprises layers of molybdenum foil that have sufficient electrical conductivity to enable the layers of molybdenum foil to act as an electrical component for a composite aircraft structure.
[0058] Advantageously, the method comprises layers of molybdenum foil that have sufficient strength, sufficient stiffness and sufficient electrical conductivity to enable the layers of molybdenum foil to act as an aircraft keel beam and a return path current to disperse electrical current from a lightning strike to a composite structure, where the composite structure is an aircraft structure.
[0059] Advantageously, the method comprises layers of molybdenum foil that have sufficient electrical conductivity and sufficient thermal conductivity to enable layers of molybdenum foil to act as electrical energy dissipation trajectories that enhance a radius attenuation of a composite structure.
[0060] Advantageously, the method comprises layers of molybdenum foil that have a sufficient melting point and sufficient thermal conductivity that enable layers of molybdenum foil to act as thermal penetration barriers and thermal energy dissipation paths that enhance the thermal shock resistance of a composite structure.
[0061] Advantageously, the method comprises layers of molybdenum foil that have sufficient thermal conductivity to enable layers of molybdenum foil to act as thermal and temperature controllers that enhance a curing cycle of a composite structure.
[0062] Advantageously, the method comprises layers of molybdenum foil that have sufficient stiffness and sufficient strength to enable layers of molybdenum foil to act as load dissipation paths that enhance the impact durability of a composite structure.
[0063] Advantageously, the method comprises the layers of molybdenum foil that have sufficient stiffness and sufficient strength to enable the layers of molybdenum foil to act as load routing paths that direct load around non-load bearing areas. in a composite structure.
[0064] Advantageously, the method comprises layers of molybdenum foil that have sufficient stiffness and sufficient strength to enable the layers of molybdenum foil to act as reinforcing elements and load extraction paths to reinforce and extract cargo away. of a repair area in a composite structure.
[0065] Advantageously, the method comprises layers of molybdenum foil that have sufficient stiffness and sufficient strength to enable the layers of molybdenum foil to act as fiber stabilizers that attenuate fiber distortion in a composite structure.
[0066] In accordance with another additional aspect of the present invention, a system is provided to monitor the structural health of a composite structure, the system comprising a composite structure comprising one or more hybrid molybdenum composite laminates, wherein each laminate includes a plurality of layers of composite material; a plurality of surface-treated molybdenum sheet layers interlaced between the layers of composite material; and a plurality of adhesive layers disposed between and connecting the adjacent layers of the layers of composite material and the layers of molybdenum sheet, and, one or more electrical sensor devices coupled to one or more laminates, the sensor devices directing the electrical current through the layers of molybdenum sheet and monitor any changes in the flow of electrical current through the layers of molybdenum in order to obtain structural health data from the composite structure by means of one or more signals from one or more sensor devices .
[0067] Advantageously, the system comprises layers of molybdenum foil that have sufficient stiffness to leverage a fiber tensile strength and a fiber stiffness outside the geometric axis in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers, the molybdenum sheet layers being separated from each other and additionally having sufficient electrical conductivity to enable the molybdenum sheet layers to act as an electrical bus.
[0068] Advantageously, the system comprises structural health data that is selected from the group comprising one or more of lightning strike detection, structural failure initiation, structural failure propagation, potential deterioration, actual deterioration and data from structural health detected through a complete or partial interruption of electrical current.
[0069] Advantageously the system in which the composite structure comprises an aircraft structure.
[0070] In accordance with another aspect of the present invention, a method is provided to monitor the structural health of a composite structure using the layers of molybdenum sheet, the method of which includes treating one surface of each of a plurality of layers of molybdenum sheet; interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; coupling one or more electrical sensor devices to one or more laminates; directing the electrical current through the layers of molybdenum sheet with one or more electrical sensor devices; monitor any change in the flow of electrical current through the layers of molybdenum sheet with one or more electrical sensor devices; and obtaining structural health data for the composite structure via one or more signals from one or more electrical sensor devices.
[0071] Advantageously, the method comprises layers of molybdenum sheet that have sufficient stiffness to leverage the fiber tensile strength and fiber stiffness of the fibers outside the geometric axis in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers, the molybdenum sheet layers being separated from each other and additionally having sufficient electrical conductivity to enable the molybdenum sheet layers to act as an electrical bus.
[0072] Advantageously, the method comprises structural health data that is selected from the group comprising one or more of lightning strike detection, structural failure initiation, structural failure propagation, potential deterioration, actual deterioration and data from structural health detected through interruption of complete or partial electrical current.
[0073] Advantageously the method in which the composite structure comprises an aircraft structure.
[0074] In accordance with yet another aspect of the present invention, a method of fabricating an electric bus in an aircraft structure using the layers of molybdenum sheet is provided, the method including treating a surface of each one within one plurality of layers of molybdenum sheet; interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers acting as an electrical bus; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and manufacture the molybdenum composite hybrid laminate electric bus in an aircraft structure.
[0075] Advantageously, the method comprises layers of molybdenum sheet that have sufficient stiffness to leverage fiber tensile strength and fiber stiffness outside the geometrical layer in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers, the molybdenum sheet layers being separated from each other and additionally having sufficient electrical conductivity to enable the molybdenum sheet layers to act as the electrical bus in the aircraft structure, resulting in an overall weight aircraft structure.
[0076] Advantageously, the method in which the interlacing and bonding comprise one or more of compacting, consolidating and curing the interlaced treated surface molybdenum sheet layers and the composite material layers.
[0077] Advantageously, the method comprises treating the surface of the molybdenum sheet layers which comprises one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and etching by chemical corrosion.
[0078] In accordance with yet another aspect of the present invention, a method of fabricating an aircraft keel beam in order to disperse electrical current from a lightning strike is provided in an aircraft structure, the method using the foil layers. molybdenum, wherein the method includes treating one surface of each of a plurality of layers of molybdenum sheet; interweave the molybdenum sheet layers of the treated surface with a plurality of layers of composite material, the molybdenum sheet layers being an aircraft composite keel beam and current return path that disperses the electrical current from a fall. radius for an aircraft structure; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and use the composite molybdenum hybrid laminate in the aircraft structure to disperse the electrical current from the lightning strike to the aircraft structure.
[0079] Advantageously, the method comprises layers of molybdenum foil that have sufficient stiffness to leverage fiber tensile strength and fiber stiffness outside the geometrical layer in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers and in the molybdenum sheet layers additionally have sufficient strength, sufficient stiffness and sufficient electrical conductivity to enable the molybdenum sheet layers to act as the aircraft keel beam and the return path of current to disperse the electrical current from the lightning strike to the aircraft structure.
[0080] Advantageously, the method in which the interlacing and bonding additionally comprise one or more of compacting, consolidating and curing the interlaced treated surface molybdenum sheet layers and the composite material layers.
[0081] Advantageously, the method comprises treating the surface of the molybdenum sheet layers which comprises one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and etching by chemical corrosion.
[0082] In accordance with yet another aspect of the present invention, a method of improving the radius attenuation of a composite structure using the layers of molybdenum sheet is provided, the method including treating a surface of each one among a plurality of layers of molybdenum sheet; interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, with the molybdenum sheet layers being electrical energy dissipation trajectories enhance a radius attenuation of a composite structure; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and use the composite molybdenum hybrid laminate in the composite structure to improve the radius attenuation of the composite structure.
[0083] Advantageously, the method comprises layers of molybdenum sheet that have sufficient stiffness to leverage a fiber tensile strength and fiber stiffness outside the geometric axis in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers and the molybdenum sheet layers additionally have sufficient electrical conductivity and sufficient thermal conductivity to enable the molybdenum sheet layers to act as electrical energy dissipation trajectories that enhance the radius attenuation of the composite structure .
[0084] Advantageously, the method comprises interlacing and bonding which additionally comprise one or more of compacting, consolidating and curing the interlaced treated surface molybdenum sheet layers and the composite material layers.
[0085] Advantageously, the method comprises the surface treatment of the molybdenum sheet layers comprising one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting , sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and chemical corrosion engraving.
[0086] In accordance with an additional aspect of the present invention, a method of improving the thermal shock resistance of a composite structure using the layers of molybdenum sheet is provided, the method including treating a surface of each one among a plurality of layers of molybdenum sheet; interweave the surface-treated molybdenum sheet layers with a plurality of layers of composite material, with the molybdenum sheet layers being thermal penetration barriers and thermal energy dissipation paths that enhance the thermal shock resistance of a composite structure ; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and use the composite molybdenum hybrid laminate in the composite structure to improve the thermal shock resistance of the composite structure.
[0087] Advantageously, the method comprises layers of molybdenum sheet which have sufficient stiffness to leverage a fiber tensile strength and fiber stiffness of the fibers outside the geometrical layer in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers and the molybdenum sheet layers additionally have a sufficient melting point and sufficient thermal conductivity to enable the molybdenum sheet layers to act as thermal penetration barriers and thermal energy dissipation paths that enhance the resistance to thermal shock of the composite structure.
[0088] Advantageously, the method comprises interlacing and bonding which additionally comprise one or more of compacting, consolidating and curing the interlaced treated surface molybdenum sheet layers and the composite material layers.
[0089] Advantageously, the method comprises the surface treatment of the molybdenum sheet layers comprising one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting , sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and chemical corrosion engraving.
[0090] In accordance with another additional aspect of the present invention, a method of improving a curing cycle of a composite structure using the layers of molybdenum sheet is provided, the method including treating a surface of each one among a plurality of layers of molybdenum sheet; interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being thermal and temperature controllers that enhance a curing cycle of a composite structure; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and use the composite molybdenum hybrid laminate in the composite structure to improve the curing cycle of the composite structure.
[0091] Advantageously, the method comprises layers of molybdenum foil that have sufficient stiffness to leverage a fiber tensile strength and fiber stiffness outside the geometrical layer in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers and the molybdenum sheet layers additionally have sufficient thermal conductivity to enable the molybdenum sheet layers to act as thermal and temperature controllers that enhance the curing cycle of the composite structure.
[0092] Advantageously, the method comprises interlacing and bonding which additionally comprise one or more of compacting, consolidating and curing the interlaced treated surface molybdenum sheet layers and the composite material layers.
[0093] Advantageously, the method comprises the surface treatment of the molybdenum sheet layers comprising one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting , sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and chemical corrosion engraving.
[0094] Advantageously, the method comprises the layers of molybdenum foil that act as thermal and temperature controllers to enhance the curing cycle characteristics selected from the group comprising a curing cycle extension, a thermal leveling of the curing cycle. curing, a cure cycle temperature leveling, a cure cycle thermal control and a cure cycle temperature control.
[0095] In accordance with yet another additional aspect of the present invention, a method of improving the durability of impact of a composite structure using the layers of molybdenum sheet is provided, the method including treating a surface of each one among one. plurality of layers of molybdenum sheet; interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being load-dissipating paths that enhance the impact durability of a composite structure; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and use the composite molybdenum hybrid laminate in the composite structure to improve the impact durability of the composite structure.
[0096] Advantageously, the method comprises layers of molybdenum sheet that have sufficient stiffness to leverage a fiber tensile strength and fiber stiffness of the fibers outside the geometrical layer in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers and the molybdenum sheet layers additionally have sufficient stiffness and sufficient strength to enable the molybdenum sheet layers to act as load dissipation paths that enhance the impact durability of the composite structure.
[0097] Advantageously, the method comprises interlacing and bonding which further comprise one or more of the compacting, consolidation and curing of the interwoven treated surface molybdenum sheet layers and the composite material layers.
[0098] Advantageously, the method comprises the surface treatment of the molybdenum sheet layers comprising one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting , sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and chemical corrosion engraving.
[0099] Advantageously, the method comprises the composite structure that comprises an aircraft and additionally comprises the layers of molybdenum sheet that improve the resistance to impact damage that comprise collisions with hail or birds.
[00100] In accordance with yet another additional aspect of the present invention, a method of directing cargo around non-load bearing areas is provided in a composite structure using the layers of molybdenum sheet, the method including treating a surface of each of a plurality of layers of molybdenum sheet; interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, with the molybdenum sheet layers being load routing paths that direct load around non-load bearing areas in a composite structure; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and use the composite molybdenum hybrid laminate in the composite structure to direct the load around the non-load bearing areas in the composite structure.
[00101] Advantageously, the method comprises layers of molybdenum sheet that have sufficient stiffness to leverage a fiber tensile strength and fiber stiffness of the fibers outside the geometrical layer in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers and the molybdenum sheet layers additionally have sufficient stiffness and sufficient strength to enable the molybdenum sheet layers to act as load routing paths that direct cargo around non-load bearing areas in the composite structure.
[00102] Advantageously, the method comprises interlacing and bonding which additionally comprise one or more of compacting, consolidating and curing the interlaced treated surface molybdenum sheet layers and the composite material layers.
[00103] Advantageously, the method comprises the surface treatment of the molybdenum sheet layers comprising one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting , sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and chemical corrosion engraving.
[00104] Advantageously, the method comprises the non-load bearing areas that are selected from the group comprising access holes, access panels and system penetrations.
[00105] In accordance with yet another additional aspect of the present invention, a method of reinforcing and extracting the load away from a repair area in a composite structure using the layers of molybdenum sheet is provided, the method including treating a surface of each of a plurality of layers of molybdenum sheet; interweave the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being reinforcing elements and load extraction paths that reinforce and extract the load away from a repair area in a composite structure; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and use the composite molybdenum hybrid laminate on the composite structure to reinforce and extract load away from the repair area on the composite structure.
[00106] Advantageously, the method comprises layers of molybdenum sheet which have sufficient stiffness to leverage a fiber tensile strength and fiber stiffness of the fibers outside the geometrical layer in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers and the molybdenum sheet layers additionally have sufficient stiffness and sufficient strength to enable the molybdenum sheet layers to reinforce and extract load away from the repair area in the composite structure.
[00107] Advantageously, the method comprises interlacing and bonding which further comprise one or more of the compacting, consolidation and curing of the interwoven treated surface molybdenum sheet layers and the composite material layers.
[00108] Advantageously, the method comprises the surface treatment of the molybdenum sheet layers which comprises one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting , sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and chemical corrosion engraving.
[00109] Advantageously, the method comprises the repair areas that are selected from the group comprising a patch repair area, a chamfer repair area, holes, weakened areas and damaged areas.
[00110] In accordance with yet another additional aspect of the present invention, a method of attenuating fiber distortion in a composite structure using the layers of molybdenum sheet is provided, the method including treating a surface of each one among a plurality of layers of molybdenum sheet; interweaving the surface-treated molybdenum sheet layers with a plurality of layers of composite material, the molybdenum sheet layers being fiber stabilizers that attenuate fiber distortion in a composite structure; bonding each layer of surface-treated molybdenum sheet to the adjacent composite material layers with an adhesive layer to form a hybrid composite molybdenum laminate that has the improved conventional yield strength; and use the composite molybdenum hybrid laminate in the composite structure to mitigate fiber distortion in the composite structure.
[00111] Advantageously, the method comprises layers of molybdenum foil that have sufficient stiffness to leverage a fiber tensile strength and fiber stiffness of the fibers outside the geometric axis in adjacent composite material layers by means of Poisson effects in the molybdenum sheet layers and the molybdenum sheet layers additionally have sufficient stiffness and sufficient strength to enable the molybdenum sheet layers to act as fiber stabilizers that attenuate fiber distortion in the composite structure.
[00112] Advantageously, the method comprises interlacing and bonding which further comprise one or more of the compacting, consolidation and curing of the interwoven treated surface molybdenum sheet layers and the composite material layers.
[00113] Advantageously, the method comprises the surface treatment of the molybdenum sheet layers comprising one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting , sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning and chemical corrosion engraving.
[00114] The features, functions and advantages that have been discussed can be achieved independently in various modalities of the description or can be combined in still other modalities whose additional details can be seen with reference to the drawings and description below. BRIEF DESCRIPTION OF THE DRAWINGS
[00115] The description can be better understood with reference to the detailed description below considered in conjunction with the accompanying drawings that illustrate exemplary and preferred modalities, but which are not necessarily drawn to scale, where:
[00116] Figure 1 is an illustration of a perspective view of an aircraft that can incorporate one or more advantageous modalities of a hybrid molybdenum composite laminate of the description;
[00117] Figure 2 is an illustration of a flowchart of an aircraft production and service methodology;
[00118] Figure 3 is an illustration of an aircraft functional block diagram;
[00119] Figure 4 is an illustration of a functional block diagram of one of the modalities of a hybrid molybdenum composite laminate of the description;
[00120] Figure 5 is an illustration of a partial isometric cross-sectional view of one of the molybdenum laminate stacking modalities of the description;
[00121] Figure 6 is a side cross-sectional view of another among the modalities of a stack of molybdenum laminate of the description;
[00122] Figure 7 is an illustration of a schematic diagram of fibers outside the geometric axis levered through Poisson effects in the treated surface molybdenum sheet layer;
[00123] Figure 8 is an illustration of a schematic diagram of one of the modalities of a hybrid composite molybdenum laminate of the description in which layers of molybdenum sheet act as an electric bus;
[00124] Figure 9 is an illustration of a schematic diagram of another among the modalities of a hybrid composite molybdenum laminate of the description in which the layers of molybdenum sheet act as electrical energy dissipation paths for an improved radius attenuation;
[00125] Figure 10 is an illustration of a schematic diagram of another among the modalities of a hybrid composite molybdenum laminate of the description in which the layers of molybdenum sheet act as barriers against thermal penetration and thermal energy dissipation paths for a improved thermal shock resistance;
[00126] Figure 11 is an illustration of a schematic diagram of another among the modalities of a hybrid molybdenum composite laminate of the description in which the layers of molybdenum sheet act as load dissipation paths for enhanced durability against impact;
[00127] Figure 12A is an illustration of a schematic diagram of another among the modalities of a hybrid composite molybdenum laminate of the description in which the layers of molybdenum sheet act as trajectories for directing cargo to non-load bearing areas;
[00128] Figure 12B is an illustration of a schematic diagram of a cross-section taken on lines 12B-12B of Figure 12A;
[00129] Figure 13 is an illustration of a schematic diagram of another among the modalities of a hybrid composite molybdenum laminate of the description in which the layers of molybdenum sheet act as thermal and temperature controllers to improve a curing cycle;
[00130] Figure 14A is an illustration of a schematic diagram of another among the modalities of a hybrid composite molybdenum laminate of the description in which the layers of molybdenum sheet act as reinforcement elements and load extraction paths for an area of patch repair;
[00131] Figure 14B is an illustration of a schematic diagram of a cross-section taken on lines 14B-14B of Figure 14A;
[00132] Figure 14C is an illustration of a schematic diagram of another among the modalities of a hybrid composite molybdenum laminate of the description in which the layers of molybdenum sheet act as reinforcement elements and load extraction paths for an area of chamfer repair;
[00133] Figure 14D is an illustration of a schematic diagram of a cross-section taken on lines 14D-14D of Figure 14C;
[00134] Figure 15 is an illustration of a schematic diagram of another among the modalities of a hybrid composite molybdenum laminate of the description in which the layers of molybdenum sheet acting as an aircraft composite keel beam and a return path currents to disperse electrical current from lightning strikes;
[00135] Figure 16 is an illustration of a functional block diagram, one of the exemplary modalities of a system for monitoring the structural health of a composite structure of the description;
[00136] Figure 17 is an illustration of a schematic diagram of a composite structure that has areas of fiber distortion;
[00137] Figure 18 is an illustration of a schematic diagram of another among the modalities of a hybrid composite molybdenum laminate of the description in which the layers of molybdenum sheet acting as fiber stabilizers; and,
[00138] Figures 19 to 29 are flowcharts that illustrate exemplary modalities of methods of the description. DETAILED DESCRIPTION
[00139] The described modalities will now be described more fully hereinafter in reference to the attached drawings, in which part of, but not all, the described modalities are shown. In fact, many different modalities can be provided and should not be interpreted as limited to the modalities presented in this document. Instead, these modalities are provided so that this description will be thorough and complete and will completely convey the scope of the description to those skilled in the art.
[00140] Now, referring to the figures, Figure 1 is an illustration of a perspective view of an exemplary aircraft structure 10 that can incorporate one or more advantageous modalities of a hybrid molybdenum composite laminate 100 (see Figure 4 ) of the description. As shown in Figure 1, the aircraft structure 10 comprises a fuselage 12, a nose 14, a cockpit 16, wings 18 operatively coupled to the fuselage 12, one or more propulsion units 20, a vertical tail stabilizer 22 , one or more horizontal tail stabilizers 24 and one or more keel beams 26. The aircraft structure 10 can be made of composite and / or metallic materials that can be used in such portions of the aircraft structure 10, which include, but are not limited to, not limited, the fuselage 12, the nose 14, the wings 18, the vertical tail stabilizer 22, the one or more horizontal tail stabilizers 24 and the one or more keel beams 26. Although aircraft 10 shown in Figure 1 is generally representative of a commercial passenger aircraft, the composite molybdenum hybrid laminate 100, as described in this document, can also be used in other types of aircraft. More specifically, the teachings of the described modalities can be applied to another passenger aircraft, cargo aircraft, military aircraft, helicopter and other types of aircraft or air vehicles, as well as aerospace vehicles, satellites, space launch vehicles, rockets and other vehicles aerospace. It can also be appreciated that the modalities of methods, systems and apparatus according to the description can be used in other vehicles, such as boats and other vessels, trains, automobiles, trucks and buses.
[00141] Figure 2 is an illustration of a flowchart of an aircraft service and production methodology 30. Figure 3 is an illustration of a functional block diagram of an aircraft 50. In relation to Figures 2-3, the modalities of the description can be described in the context of the aircraft manufacturing and service method 30 as shown in Figure 2 and aircraft 50 as shown in Figure 3. During pre-production, the exemplificative method 30 may include a specification and design 32 of aircraft 50 and material acquisition 34. During production, a component and subassembly manufacture 36 and an integration system 38 of aircraft 50 take place. After that, aircraft 50 can be certified and delivered 40 in order to be put into service 42. While in service 42 by a customer, aircraft 50 is scheduled for routine maintenance and service 44 (which can also include modification, reconfiguration, renewal, and so on).
[00142] Each of the method 30 processes can be performed or executed by a system integrator, a third party and / or an operator (for example, a customer). For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and main system subcontractors; a third party may include without limitation any number of sellers, subcontractors and suppliers; and an operator can be an airline, rental company, military entity, service organization, and so on.
[00143] As shown in Figure 3, the aircraft 50 produced using the exemplary method 30 may include an aircraft frame 52 with a plurality of systems 54 and an interior 56. The aircraft frame 52 may incorporate one or more advantageous laminate embodiments molybdenum composite hybrid 100 (see Figure 4) of the description. Examples of high-level systems 54 include one or more of a propulsion system 58, an electrical system 60, a hydraulic system 62 and an environmental system 64. Any number of other systems can be included. Although an example of airspace is shown, the principles of the invention can be applied to other industries, such as the automotive industry.
[00144] The apparatus and methods incorporated in this document can be used during any one or more of the stages of the production and service method 30. For example, the components or subassemblies that correspond to the production process 36 can be manufactured or produced in a manner similar to the components or subassemblies produced while the aircraft 50 is in service 42. In addition, one or more apparatus modalities, method modalities or a combination thereof can be used during production stages 36 and 38, for example example, substantially by dispatching an assembly of an aircraft 50 or by reducing its cost. Similarly, one or more of the apparatus modalities, the method modalities or a combination thereof can be used while aircraft 50 is in service 42, for example, and without limitation, for maintenance and service 44.
[00145] Figure 4 is an illustration of a functional block diagram of one of the modalities of the hybrid molybdenum composite laminate 100 of the description. As shown in Figure 4, the molybdenum composite hybrid laminate 100 is provided to enhance a conventional yield strength 102 of a composite structure 104. The molybdenum composite hybrid laminate 100 comprises a plurality of layers of composite material 106. Each of the composite material layers 106 comprises a fiber-reinforced polymeric material 108. The fiber-reinforced polymeric material 108 preferably comprises fibers outside the geometrical axis 110 (see Figure 7) and the substantially parallel fibers 152 (see Figure 7) in one resin matrix 114 (see Figure 7). The fibers outside the geometrical axis 110 and the substantially parallel fibers 152 preferably comprise high modulus strengthening fibers 112 arranged in the resin matrix 114. The high modulus strengthening fibers 112 can be made of a material comprising graphite, glass, carbon , boron, ceramics, aramids, polyolefins, polyethylene, polymers, tungsten carbide or other suitable materials. The resin matrix 114 can be made of a resin material comprising thermosetting resins such as epoxies and polyesters, thermoplastic resins such as polyamides, polyolefins and fluorine polymers, hybrid polymer resins with properties of both thermoset and thermoplastic resins or other suitable resin materials. Fibers outside the geometry axis 110 and substantially parallel fibers 152 preferably have a tensile strength of fiber 116 in a range of about 3,447.38 MPa (500 KSI (thousands of pounds per square inch)) to about 6,894.76 MPa (1,000 KSI). Fibers outside the geometry axis 110 and substantially parallel fibers 152 preferably have a fiber stiffness 118 in a range of about 220.63 GPa (32 MSI (million pounds per square inch)) to about 689.47 GPa ( 100 MSI). The fibers outside the geometric axis 110 and the substantially parallel fibers 152 preferably have a fiber elongation 120 in a range of about 0.1% to about 0.5% or greater of the original fiber length. Each layer of composite material 106 preferably has a thickness in a range of about 0.0254 mm (1 mil) to about 0.50 mm (20 mils). More preferably, each layer of composite material 106 has a thickness in a range of about 0.1016 mm (4 mils) to about 0.2032 mm (8 mils).
[00146] The molybdenum composite hybrid laminate 100 further comprises a plurality of layers of surface-treated molybdenum sheet 122 interlaced between layers of composite material 106. Each of the layers of surface-treated molybdenum sheet 122 has a molybdenum stiffness sufficient 124 to leverage the tensile strength of fiber 116 and the fiber stiffness 118 of fibers outside the geometrical axis 110 in adjacent composite material layers 106 by means of Poisson effects in the treated surface molybdenum sheet layers 122. For For the purposes of this description, "Poisson effects" means the double effect that a compression load has on an object, that is, compression causes the object to become smaller in the direction of the compressive load and wider laterally. For each different type of material, there is a specific stress ratio in the axial direction to tension in the transverse direction, and this is called the "Poisson ratio". The stiffness of molybdenum 124 comprises 324.05 GPa (47 MSI (million pounds per square inch)). The high hardness of molybdenum 124 of the surface-treated molybdenum sheet layer 122 allows the surface-treated molybdenum sheet layer 122 to leverage the tensile strength of fiber 116 and the fiber stiffness 118 of fibers outside the 110 axis in the fiber-reinforced polymeric material 108 through Poisson effects in the treated surface molybdenum sheet layer 122 and prevents fibers outside the geometrical axis 110 and substantially parallel fibers 152 in fiber-reinforced polymeric material 108 from bending under compression.
[00147] Figure 7 is an illustration of a schematic diagram of the fibers outside the geometric axis 110 leveraged through Poisson effects in the layer of molybdenum sheet of the treated surface 122. Figure 7 shows the fibers outside the geometric axis 110 that comprise high modulus strengthening fibers 112 in the resin matrix 114 and shows substantially parallel fibers 152 in the resin matrix 114 and in a D direction of a loading path 154. The design of the composite molybdenum hybrid laminate 100 allows for a leverage of the resistance of both substantially parallel fibers 152 running in a D direction of a loading path 154, and the treated surface molybdenum sheet layer 122 allow leverage of the fiber tensile strength 116 and fiber stiffness 118 of the fibers outside the geometry axis 110. In addition, the surface-treated molybdenum sheet layer 122 may be constrained and may not act in a standard way of effect and Poisson. Furthermore, a triaxial loading state, that is, a state in which there is significant stress that is applied in all three directions x, y, and z, exists in the treated surface molybdenum sheet layer 122 to increase a yield point actual or conventional yield strength of the surface treated molybdenum sheet layer 122 depending on the bond strength of the treated surface molybdenum sheet layer 122. Increasing the actual yield point or the conventional yield strength allows an additional bonding z applied to the molybdenum sheet via the bond.
[00148] As shown in Figure 4, each of the surface-treated molybdenum sheet layers 122 additionally has a molybdenum resistance 126. Preferably, the molybdenum resistance 126 is in a range of about 861.84 MPa (125 KSI (thousands of pounds per square inch)) at about 1,103.16 MPa (160 KSI). As shown in Figure 4, each of the surface-treated molybdenum sheet layers 122 additionally has an electrical conductivity of molybdenum 128. Preferably, the electrical conductivity of molybdenum 128 is about 17.9 x 106 1 / 0hm-m ( Ohm-meter). As shown in Figure 4, each of the surface-treated molybdenum sheet layers 122 additionally has a thermal conductivity of molybdenum 130. Preferably, the thermal conductivity of molybdenum 130 is about 138 W nr1K'1. (Watts per meter Kelvin). As shown in Figure 4, each of the surface-treated molybdenum sheet layers 122 additionally has a molybdenum melting point 132. Each surface-treated molybdenum sheet layer 122 preferably has a thickness in the range of about 0, 0254 mm (1 mil) to about 1.016 mm (40 mil).
[00149] Surface-treated molybdenum sheet layers 122 are preferably surface-treated in order to enhance a bond between the surface-treated molybdenum sheet layer interface 122 with an adjacent layer of composite material 106. The sheet layer surface-treated molybdenum material 122 is preferably surface-treated by means of one or more surface treatments comprising a surface sol-gel treatment, a water-based sol-gel paint, abrasive blasting, sanding, sandblasting, scrubbing with solvent, abrasion, chemical cleaning, chemical corrosion engraving, laser ablation or other suitable surface treatment. Useful surface treatment processes are described, for example, in U.S. Patent Documents 3,959,091; No. 3,989,876; US 4,473,446; and US 6,037,060, all of which are incorporated herein by reference.
[00150] The hybrid molybdenum composite laminate 100 further comprises a plurality of adhesive layers 134 disposed between it and connecting adjacent layers of the layers of composite material 106 and the layers of molybdenum sheet of treated surface 122. The adhesive layer 134 preferably comprises an adhesive made of a material such as thermosetting epoxy resin adhesives, epoxy adhesives, thermoplastic adhesives, polyimide adhesives, bismaleimide adhesives, polyurethane adhesives, reinforced acrylic adhesives or other suitable adhesive. Each adhesive layer 134 preferably has a thickness in the range of about 0.0127 mm (0.5 mil) to about 0.0508 mm (2.0 mils). Preferably, adhesive layer 134 provides a minimal adhesive to wet a surface 125a or 125b (see Figure 6) of the molybdenum sheet layer 122 to facilitate bonding with the adjacent layer of composite material 106.
[00151] The molybdenum composite hybrid laminate 100 is used in composite structure 104 and improves a conventional yield strength 102 (see Figure 4) in composite structure 104. Composite structure 104 can comprise an aircraft structure 10 (see Figure 1) or other suitable composite structure. The hybrid molybdenum composite laminate 100 is preferably designed for low temperature applications, such as a temperature of less than about 259.99 degrees Celsius (500 degrees Fahrenheit). Exemplary low temperature applications may include a use of the molybdenum 100 composite hybrid laminate for external subsonic aircraft parts and substructures located away from one or more propulsion units 20 (see Figure 1), such as aircraft jet engines .
[00152] Figure 5 is an illustration of a partial isometric cross-sectional view of one of the 101 molybdenum laminate stacking modalities of the description. As shown in Figure 5, the stack of molybdenum laminate 101 comprises a plurality of layers of composite material 106 and a plurality of layers containing molybdenum sheet 146 interlaced between the layers of composite material 106. Each of the layers of composite material 106 , as discussed in detail above, preferably comprises a fiber-reinforced polymeric material 108. Each layer containing molybdenum sheet 146 comprises a layer of composite material 106, preferably comprising fiber-reinforced polymeric material 108, wherein the layer of composite material 106 may have a cutout portion 144 of molybdenum sheet 123 that can be surface treated. As additionally shown in Figure 5, the stack of molybdenum laminate 101 further comprises the adhesive layers 134 disposed therebetween and which joins the adjacent layers of the layers of composite material 106 and the layers facing each other containing molybdenum sheet 146. The molybdenum laminate stack 101 can additionally comprise one or more layers of surface-treated molybdenum sheet 122 adjacent to one or more layers of composite material 106 and / or adjacent to one or more layers containing molybdenum sheet 146. As shown in Figure 5, the surface-treated molybdenum sheet layer 122 is adjacent to a layer of composite material 106 and is bonded to the layer of composite material 106 with an adhesive layer 134.
[00153] As shown in Figure 5, each blade or substrate 136 of the molybdenum laminate stack 101 has a first face 138 and a second face 140 spaced from one another and extending to an end edge 142. As additionally shown in Figure 5, in areas of the molybdenum laminate stacking 101 that require specific reinforcement with the surface-treated molybdenum sheet 123, the cutout portion 144 may be formed in the layer containing molybdenum sheet 146. The cutout portion 144 may be formed, for example, by removing the composite material layer 106 to an inner edge 148 (see Figure 5), or by stacking the composite material layer 106 to the inner edge 148, leaving the formed cutout portion 144. Stacking devices suitable for forming cutout portions 144 may comprise, for example, known contouring tape (CTLM) laying machines (not shown), such as those manufactured by Cincinnati Machine, Inc. of Cincinnati, Ohio. The layer containing molybdenum sheet 146 can then be completed with the surface-treated molybdenum sheet 123 to substantially fill each cutout portion 144. The layer containing molybdenum sheet 146 comprises the layer of composite material 106 that extends between the the first face 138 and the second face 140 and has the lower edge 148 which defines the cutout portion 144. The layer containing molybdenum sheet 146 further comprises the surface-treated molybdenum sheet 123 which extends between the first face 138 and the second face 140 substantially from the inner edge 148 that fills the cutout portion 144.
[00154] As additionally shown in Figure 5, in which multiple layers containing molybdenum sheet 146 will be broken, the inner edges 148 of the cutout portions 144 can be scaled to prevent overlapping of two or more inner edges 148 in order to provide improved load distribution by the surface treated molybdenum sheet 123. The stepped inner edges 148 of the cutout portions 144 can also minimize or eliminate a possible resin build-up that can occur at the ends of the surface treated molybdenum sheet 123. the surface-treated molybdenum sheet 123, as well as breaking the composite material layer 106 into a single layer containing molybdenum sheet 146 with the surface-treated molybdenum sheet 123 according to the description can yield different properties in laminate stacking resulting molybdenum 101.
[00155] Figure 6 is a side cross-sectional view of another among the modalities of a stack of molybdenum laminate 150 of the description. As shown in Figure 6, layers of composite material 106 and layers containing molybdenum sheet 146 can be oriented at angles of approximately -45 (minus forty-five) degrees, approximately +45 (plus forty-five) degrees, approximately 0 (zero) degree or approximately 90 (ninety) degrees in a particular modality. Each layer containing molybdenum sheet 146 comprises the composite material layer 106 which has the cut-out portion 144 of surface-treated molybdenum sheet 123. With the stacking of molybdenum laminate 150, as well as the stacking of molybdenum laminate 101 ( see Figure 5), preferably none of the two adjacent layers are oriented at the same angle, that is, an adjacent layer of composite material 106 and a layer containing molybdenum sheet 146 are not oriented at the same angle, an adjacent layer of composite material 106 and a layer of surface treated molybdenum sheet 122 are not oriented at the same angle, and an adjacent layer containing molybdenum sheet 146 and a layer of surface treated molybdenum sheet 122 are not oriented at the same angle.
[00156] In another embodiment of the description, a composite molybdenum hybrid laminate 100 is provided that has layers of molybdenum foil 122 that act as an electrical bus 160 (see Figure 8) in composite structure 104 (see Figure 4), such as an aircraft frame 10 (see Figure 1). Figure 8 is an illustration of a schematic diagram of one of the molybdenum 100 composite hybrid laminate modalities of the description in which the treated surface molybdenum sheet layers 122 act as the electrical bus 160. For the purposes of this application, a electrical bus means a distribution point in an aircraft electrical system from which electrical charges derive their power. The surface-treated molybdenum sheet layers 122 have sufficient molybdenum electrical conductivity 128 (see Figure 4) to allow the surface-treated molybdenum sheet layers 122 to act as the electrical bus 160 to integrate separate electrical and structural systems (not shown) on a single system 158 (see Figure 8) for composite structure 104 (see Figure 4), such as aircraft structure 10 (see Figure 1), resulting in a reduced overall weight of the aircraft 10.
[00157] As discussed above, the molybdenum composite hybrid laminate 100 comprises a plurality of layers of composite material 106 (see Figure 8). Each layer of composite material 106 comprises a fiber-reinforced polymeric material 108 (see Figure 4). Preferably, the composite material layer 106 comprises a resin / graphite-based material layer 164 (see Figure 8). The hybrid molybdenum composite laminate 100 further comprises a plurality of surface-treated molybdenum sheet layers 122 (see Figure 8) interlaced between the layers of composite material 106 (see Figure 8). The surface-treated molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage fiber tensile strength 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of the fibers outside the geometrical axis 110 (see Figure 4) in the adjacent composite material layers 106 through Poisson effects in the treated surface molybdenum sheet layers 122. The laminated composite molybdenum hybrid laminate additionally comprises a plurality of layers adhesive 134 (see Figure 8) arranged between and connecting the adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122.
[00158] In this embodiment, preferably, the treated surface molybdenum sheet layers 122 are separated from each other and have sufficient molybdenum electrical conductivity 128 (see Figure 4) to enable the treated surface molybdenum sheet layers 122 act like the electric bus 160. Molybdenum is an excellent electrical conductor. It is this low electrical resistance characteristic that enables the treated surface molybdenum sheet layers 122 to act as an excellent electrical bus for a wide range of electrical applications in composite structure 104 (see Figure 4), such as the aircraft structure 10 (see Figure 1). Preferably, the composite molybdenum hybrid laminate 100 comprises multiple layers of surface-treated molybdenum sheet 122 in the composite structure 104 and, consequently, several discrete conductors may be available. Each of the surface-treated molybdenum sheet layers 122 may comprise strips that are electrically separated from each other, and each of these layers or strips may act as individual circuit legs 162 (see Figure 8) of a separate circuit. Adhesive layers 134 (see Figure 8) can act as electrical insulating layers 166 (see Figure 8) for the treated surface molybdenum sheet layers 122 when separate circuits are desired. The electrical current (/) 170 (see Figure 8) can be conducted through the individual layers of the treated surface molybdenum sheet layers 122 as the flow of electrical current 172 (see Figure 8) moves through the system single 158 (see Figure 8). This modality can integrate the electrical requirements of the electrical system and the structural requirements of the structural system in the single system 158, resulting in significant weight reductions.
[00159] In another embodiment, a method 430 of manufacturing an electric bus 160 (see Figure 8) in a composite structure 104 (see Figure 4), such as an aircraft structure 10 (see Figure 1) is provided , using layers of molybdenum sheet 122 (see Figure 8). Figure 21 is a flowchart that illustrates one of the exemplary modalities of method 430 for manufacturing the electric bus 160. Method 430 comprises step 432 of treating a surface 125a or 125b (see Figure 6) of each of a plurality of molybdenum foil layers 122. The surface treatment 125a or 125b of the molybdenum foil layers 122 may comprise one or more surface treatments comprising surface gel sol treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning, chemical etching, or other suitable surface treatment.
[00160] Method 430 further comprises step 434 of interweaving the surface-treated molybdenum sheet layers 122 with a plurality of layers of composite material 106 (see Figure 8). The molybdenum sheet layers 122 act as an electrical bus 160 (see Figure 8). The molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage a fiber tensile strength 116 (see Figure 4) and a fiber stiffness 118 (see Figure 4) of the fibers outside of the geometry axis 110 (see Figure 4) in the adjacent composite material layers 106 through the Poisson effects in the molybdenum foil layers 122. The molybdenum foil layers 122 are preferably separated from each other and additionally have an electrical conductivity of sufficient molybdenum 128 (see Figure 4) to enable the layers of molybdenum sheet 122 to act as the electric bus 160 in the aircraft structure 10. The electric bus 160 can integrate separate electrical and structural systems into a single system 158 (see Figure 8) in the aircraft structure 10, resulting, consequently, in a reduced overall weight of the aircraft structure 10.
[00161] Method 430 further comprises step 436 of bonding with an adhesive layer 134 (see Figure 8) of each of the surface-treated molybdenum sheet layers 122 to the adjacent composite material layers 106 to form a composite hybrid laminate molybdenum 100 (see Figure 8) which has an improved conventional yield limit 102 (see Figure 4). Interlacing step 434 and bonding step 436 can further comprise one or more of compacting, consolidating and curing interlaced surface treated molybdenum sheet layers 122 and composite material layers 106. Method 430 additionally comprises step 438 of manufacturing the electric bus 160 of the composite molybdenum hybrid laminate 100 in an aircraft structure 10.
[00162] In another embodiment of the description, a system 250 (see Figure 16) is provided to monitor the structural health of a composite structure 104 (see Figure 16). Figure 16 is an illustration of a functional block diagram of one of the exemplary modalities of system 250 to monitor the structural health of composite structure 104. As shown in Figure 16, system 250 comprises a composite structure 104, preferably an aircraft 10 ( see Figure 1), comprising one or more composite molybdenum hybrid laminates 100. As shown in Figure 16, each composite molybdenum hybrid laminate 100 comprises a plurality of layers of composite material 106, each layer of composite material 106 comprising one fiber-reinforced polymeric material 108. As shown in Figure 16, the molybdenum composite hybrid laminate 100 further comprises a plurality of surface-treated molybdenum sheet layers 122 interlaced between the layers of composite material 106. The molybdenum sheet layers of treated surface 122 has sufficient molybdenum stiffness 124 (consu Refer to Figure 4) to leverage the fiber tensile strength 116 (see Figure 4) and fiber stiffness (see Figure 4) of fibers outside the geometry axis 110 (see Figure 4) in the adjacent composite material layers 106 through the Poisson effects on the surface treated molybdenum sheet layers 122. The surface treated molybdenum sheet layers 122 are separated from each other and have sufficient molybdenum electrical conductivity 128 (see Figure 4) to enable the surface-treated molybdenum sheet layers 122 act as an electrical bus 160 (see Figure 16). As shown in Figure 16, the hybrid molybdenum composite laminate 100 further comprises a plurality of adhesive layers 134 arranged between and connecting adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122.
[00163] In this mode, as shown in Figure 16, system 250 additionally comprises one or more electrical sensor devices 168 coupled to one or more of the composite molybdenum hybrid laminates 100. Electrical sensor devices 168 conduct electrical current 170 (see Figure 16) through the treated surface molybdenum sheet layers 122 and monitor any changes in the flow of electrical current 172 (see Figure 16) through the treated surface molybdenum sheet layers 122 to obtain structural health data 254 (see Figure 16) of composite structure 104 by means of one or more signals 252 (see Figure 16) from one or more electrical sensor devices 168. Such structural health data 254 may comprise lightning strike detection , onset of structural failures, propagation of structural failures, potential deterioration, and actual deterioration, or other appropriate structural health data that may be detected by means of partial or complete electric current interruption.
[00164] The molybdenum sheet provides improved mechanical properties to composite stacks. In addition, the high electrical conductivity of molybdenum 128 enables molybdenum to act as well as an electric bus 160 (see Figure 16). Each of the surface-treated molybdenum sheet layers 122 may comprise strips which are electrically separated from each other. Each of these layers or strips can act as individual circuit legs 162 (see Figure 16) of a separate circuit. In addition, the electrical current 170 flowing in these surface-treated molybdenum sheet circuits 122 can be monitored for evidence of any potential deterioration.
[00165] The strength of each surface-treated molybdenum sheet circuit 122 can be monitored to provide evidence of sound structure. If the resistance or signal 252 changes, this can provide data on the stability of composite structure 104. This information can potentially allow for a longer life of composite structure 104, such as an aircraft structure 10 (see Figure 1), and time in greater service for aircraft structure 10 due to real access to structural health data 254 or information about the stability of composite structure 104 rather than relying only on scheduled maintenance. System 250 allows less downtime for aircraft structure 10 and enables renovation or repair of composite structures 104 when necessary.
[00166] In another embodiment of the description, a composite molybdenum hybrid laminate 100 (see Figure 9) is provided to enhance the dissipation or attenuation of radius drop 180 (see Figure 9) of a composite structure 104 (see Figure 4). Figure 9 is an illustration of a schematic diagram of another of the molybdenum 100 composite hybrid laminate modalities of the description in which the treated surface molybdenum sheet layers 122 act as electrical energy dissipation paths 186 which enhance shock resistance of high electrical energy at the high electrical energy input 182 from a high electrical shock source, such as a lightning strike 180. As shown in Figure 9, when the high electrical shock source, such as a lightning strike 180, reaches the molybdenum composite hybrid laminate 100 of a composite structure 104 (see Figure 4), the input of high electrical energy 182 occurs. The surface-treated molybdenum sheet layers 122 act as electrical energy dissipation paths 186 to quickly conduct electrical current 184 out, resulting in the dissipation or attenuation of radius drop 180 enhanced by the molybdenum 100 composite hybrid laminate. surface-treated molybdenum sheet metal 122 has a sufficient molybdenum electrical conductivity 128 (see Figure 4) that is high and a sufficient molybdenum thermal conductivity 130 (see Figure 4) that is high to enable layers of surface treated molybdenum 122 act as the electrical energy dissipation trajectories 186, thereby improving the dissipation or attenuation of radius drop 180 of the composite structure 104 (see Figure 4). The high molybdenum melting point 132 (see Figure 4), the high molybdenum thermal conductivity 130 (see Figure 4), and the high molybdenum electrical conductivity 128 (see Figure 4) of the molybdenum sheet layers. The treated surface 122 in the molybdenum composite hybrid laminate 100 enables the molybdenum composite hybrid laminate 100 to perform well while subjected to extremely high electrical input 182 (see Figure 9). The high molybdenum stiffness 124 (see Figure 4) and the high molybdenum resistance 126 (see Figure 4), together with a low thermal expansion coefficient (CTE) of the surface-treated molybdenum sheet layers 122, additionally provide improved mechanical properties. Typical molybdenum CTE values are favorably compatible with typical CTE values for composite materials used in composite stacking. For example, molybdenum can have a typical CTE value of between approximately 4.5 x 10-6 (2.5 x 10-6) to approximately 6.3 x 10-6 meters / meter / ° C (3.5 x 106 inches / inch / ° F (degrees Fahrenheit)), and composite materials used in composite stacks can have typical CTE values ranging from approximately 0.9 x 10-6 (0.5 x 10-6) to approximately 10, 8 x 10-6 meters / meter / ° C (6.0 x 10-6 inches / inch / ° F). Layers of surface-treated molybdenum sheet 122 applied to layers of composite material 106, such as, for example, layers of resin / graphite-based material 164 (see Figure 9) provide structural advantages along with dissipation or attenuation improved radius drop rate.
[00167] Each molybdenum composite hybrid laminate 100 for improving radius drop attenuation 180 of a composite structure 104 comprises a plurality of layers of composite material 106 (see Figure 9), and each layer of composite material 106 comprises a material 108 fiber-reinforced polymeric (see Figure 4). Preferably, the composite material layer 106 comprises a resin / graphite-based material layer 164. The hybrid molybdenum composite laminate 100 further comprises a plurality of surface-treated molybdenum sheet layers 122 (see Figure 9) interlaced between the composite material layers 106. As discussed above, the treated surface molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage the tensile strength of fiber 116 (see Figure 4) and the fiber stiffness 118 (see Figure 4) of the fibers outside the geometry axis 110 (see Figure 4) in the adjacent composite material layers 106 through Poisson effects in the treated surface molybdenum sheet layers 122. The layers of surface treated molybdenum sheet 122 are separated from each other and have a sufficient molybdenum electrical conductivity 128 (see Figure 4) to enable the surface-treated molybdenum sheet layers 122 to act as an electrical bus 160 (see Figure 15). The molybdenum composite hybrid laminate 100 further comprises a plurality of adhesive layers 134 (see Figure 9) arranged between and connecting the adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122. The adhesive layers 134 (see Figure 9) can act as the electrical insulation layers 166 (see Figure 9) for the surface-treated molybdenum sheet layers 122. The molybdenum composite hybrid laminate 100 is used preferably in a composite structure 104 ( see Figure 4), such as an aircraft structure 10 (see Figure 1), and improves the dissipation or attenuation of radius drop 180 of the composite structure 104.
[00168] In another embodiment of the description, a method 470 of improving radius drop attenuation 180 (see Figure 9) of a composite structure 104 (see Figure 4) is provided using layers of molybdenum sheet 122 Figure 23 is a flowchart illustrating one of the exemplary modalities of method 470 for improving radius drop attenuation 180 of composite structure 104 (see Figure 4), as well as aircraft structure 10 (see Figure 1). Method 470 comprises step 472 of treating a surface 125a or 125b (see Figure 6) of each of a plurality of layers of molybdenum sheet 122 (see Figure 9). The surface treatment 125a or 125b of the molybdenum sheet layers 122 may comprise one or more surface treatments comprising surface gel treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, rubbing with solvent, abrasion, laser ablation, chemical cleaning, chemical etching, or other suitable surface treatment.
[00169] Method 470 further comprises step 474 of interweaving the treated surface molybdenum sheet layers 122 with a plurality of layers of composite material 106 (see Figure 9). The molybdenum sheet layers 122 act as electrical energy dissipation paths 186 (see Figure 9) that enhance the radius drop attenuation 180 of a composite structure 104. The molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage a fiber tensile strength 116 (see Figure 4) and a fiber stiffness 118 (see Figure 4) of the fibers outside the geometry axis 110 (see Figure 4) in the layers of adjacent composite material 106 through Poisson effects on molybdenum foil layers 122. Molybdenum foil layers 122 additionally have sufficient molybdenum electrical conductivity 128 (see Figure 4) and sufficient molybdenum thermal conductivity 130 (see Figure 4) to enable the layers of molybdenum foil 122 to act as electrical energy dissipation paths 186 (see Figure 9) that improve drop attenuation the radius 180 (see Figure 9) of the composite structure 104 (see Figure 4).
[00170] Method 470 additionally comprises step 476 of bonding with an adhesive layer 134 (see Figure 9) of each of the surface-treated molybdenum sheet layers 122 to the adjacent composite material layers 106 (see Figure 9) to form a hybrid molybdenum composite laminate 100 (see Figure 9) that has an improved conventional yield strength 102 (see Figure 4). Interlacing step 474 and bonding step 476 can further comprise one or more of compacting, consolidating and curing interlaced surface treated molybdenum sheet layers 122 and composite material layers 106. Method 470 additionally comprises step 478 of using the molybdenum composite hybrid laminate 100 in the composite structure 104 to improve the radius drop attenuation 180 of the composite structure 104.
[00171] In another embodiment of the description, a composite molybdenum hybrid laminate 100 is provided to conduct chain and act as an aircraft composite keel beam 240 (see Figure 15) in a composite structure 104 (see Figure 4), such as on an aircraft 10 (see Figure 1). An aircraft keel beam 26, as shown in Figure 1, is typically at the bottom of fuselage 12 (see Figure 1) and essentially joins fuselage 12. Light aircraft composite structures, such as keel beams, require conductors structurally additional parasites to effectively disperse the current from a 180 lightning strike (see Figure 15). Figure 15 is an illustration of a schematic diagram of another embodiment of a hybrid molybdenum composite laminate 100 of the description in which the treated surface molybdenum sheet layers 122 act both as an aircraft keel beam 240 and as paths. current return 242 for lightning strikes 180. As shown in Figure 15, when the shock source of high electrical power, such as a lightning strike 180, reaches the molybdenum composite hybrid laminate 100 of a composite structure 104 ( see Figure 4), high electrical power input 182 occurs. The electric current 184 (see Figure 15) can be conducted by the layers of surface treated molybdenum sheet 122 in the composite hybrid laminate of molybdenum 100. The layers of surface treated molybdenum sheet 122 provide superior molybdenum resistance 126 (see Figure 4) and upper molybdenum stiffness 124 (see Figure 4) of composite structure 104. In addition, the high electrical conductivity of molybdenum 128 (see Figure 4) of the treated surface molybdenum sheet layers 122 allows the layers surface-treated molybdenum sheet 122 act as well as an electrical bus 160 (see Figure 15). In addition, the surface-treated molybdenum sheet layers 122 can act as current return paths 242 to quickly conduct electrical current 184 out, resulting in radius drop protection 180 enhanced by the molybdenum 100 composite hybrid laminate. surface-treated molybdenum sheet layers 122 have sufficient molybdenum resistance 126 (see Figure 4), sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum electrical conductivity 128 (see Figure 4) for enable the surface molybdenum sheet layers 122 to act as an aircraft composite keel beam 240 (see Figure 15) that conducts electrical current 184 and provides a current return path 242 (see Figure 15) for falls from radius 180 (see Figure 15) on composite structure 104 (see Figure 4). Due to the improved mechanical properties and the ability to conduct electrical current 184, the treated surface molybdenum sheet layers 122 provide a uniquely advantageous hybrid molybdenum laminate that can effectively act as both an aircraft 240 keel beam in the design of aircraft as well as a current 242 return path for 180 lightning strikes, which can result in overall reduced weight and cost. The surface-treated molybdenum sheet layers 122 provide a high-performance, lightweight aircraft composite keel beam 240 that is effective in conducting electrical current 184 and that acts as a current return path 242 of radius drop 180.
[00172] As shown in Figure 15, each molybdenum composite hybrid laminate 100 comprises a plurality of layers of composite material 106, and each layer of composite material 106 comprises a fiber-reinforced polymeric material 108 (see Figure 4). Preferably, the composite material layer 106 comprises a resin / graphite-based material layer 164 (see Figure 10). The molybdenum composite hybrid laminate 100 further comprises a plurality of layers of surface-treated molybdenum sheet 122 interlaced between layers of composite material 106. As discussed above, the layers of surface-treated molybdenum sheet 122 have sufficient molybdenum stiffness. 124 (see Figure 4) to leverage the fiber tensile strength 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of the fibers outside the geometry axis 110 (see Figure 4) in the layers of adjacent composite material 106 through Poisson effects on the treated surface molybdenum sheet layers 122. The molybdenum sheet layers 122 additionally have sufficient molybdenum strength 126 (see Figure 4), sufficient molybdenum stiffness 124 (see Figure 4) and sufficient electrical conductivity of molybdenum 128 (see Figure 4) to enable the layers of molybdenum sheet io 122 acts as an aircraft composite keel beam 240 (see Figure 15) that conducts electrical current 184 (see Figure 15) and provides a current return path 242 (see Figure 15) for lightning strikes 180 ( see Figure 15). The molybdenum composite hybrid laminate 100 further comprises a plurality of adhesive layers 134 (see Figure 15) arranged between and connecting the adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122. The adhesive layers 134 (see Figure 15) can act as electrical insulation layers 166 (see Figure 15) for the surface-treated molybdenum sheet layers 122. The molybdenum composite hybrid laminate 100 is used preferably in a composite structure 104 (see Figure 4), such as an aircraft structure 10 (see Figure 1) and conducts electrical current 184 and provides the current return path 242 for lightning strikes 180 on the composite aircraft structure 104.
[00173] In another embodiment of the description, a method 450 of manufacture on an aircraft structure 10 (see Figure 1) of an aircraft composite keel beam 240 (see Figure 15) for dispersing electric current 184 (( refer to Figure 15) of a 180 radius drop (see Figure 15). Method 450 uses layers of molybdenum sheet 122 (see Figure 15). Figure 22 is a flowchart illustrating one of the exemplary modalities of method 450 for manufacturing the composite keel beam of aircraft 240. Method 450 comprises step 452 of treating a surface 125a or 125b (see Figure 6) of each from a plurality of molybdenum foil layers 122. The surface treatment 125a or 125b of the molybdenum foil layers 122 may comprise one or more surface treatments comprising surface gel sol treatment, water based sol gel paint, blasting abrasive, sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning, chemical etching, or other suitable surface treatment.
[00174] Method 450 further comprises step 454 of interweaving the surface-treated molybdenum sheet layers 122 with a plurality of layers of composite material 106 (see Figure 15). The molybdenum sheet layers 122 act both as an aircraft keel beam 240 (see Figure 15) and as a current return path 242 (see Figure 15) that disperses electrical current 184 from radius drop 180 to a composite structure 104 (see Figure 4) such as an aircraft structure 10 (see Figure 1). The molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage a fiber tensile strength 116 (see Figure 4) and a fiber stiffness 118 (see Figure 4) of the fibers outside of the geometry axis 110 (see Figure 4) in the adjacent composite material layers 106 through the Poisson effects in the molybdenum foil layers 122. The molybdenum sheet layers 122 additionally have sufficient molybdenum resistance 126 (see Figure 4 ), sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum electrical conductivity 128 (see Figure 4) to enable the layers of molybdenum sheet 122 to act as the composite keel beam 240 (see Figure 15) and how the current return path 242 (see Figure 15) to disperse electrical current 184 (see Figure 15) from radius drop 180 (see Figure 15) to the structure aircraft 10 (see Figure 1).
[00175] Method 450 additionally comprises step 456 of bonding with an adhesive layer 134 of each of the layers of surface-treated molybdenum sheet 122 to adjacent layers of composite material 106 to form a hybrid composite laminate of molybdenum 100 which has a limit conventional 102 enhanced elasticity (see Figure 4). The interlacing step 454 and the connecting step 456 can further comprise one or more of compacting, consolidating and curing the interlaced surface treated molybdenum sheet layers 122 and the composite material layers 106. Method 450 further comprises step 458 of using molybdenum composite hybrid laminate 100 in composite structure 104, such as aircraft structure 10 (see Figure 1), to disperse electrical current 184 (see Figure 15) from radius drop 180 to composite structure 104 , such as aircraft structure 10.
[00176] In another embodiment of the description, a composite molybdenum hybrid laminate 100 (see Figure 10) is provided to improve the thermal shock resistance 190 (see Figure 10) of a composite structure 104 (see Figure 4). Figure 10 is a schematic diagram illustration of another of the molybdenum 100 composite hybrid laminate modalities of the description in which the treated surface molybdenum sheet layers 122 act as both thermal energy dissipation paths 196 and penetration barriers. thermal 198 that enhance thermal shock resistance 190 for high thermal energy input 192 from thermal shock 190, such as a laser beam or X-ray. In this embodiment, the treated surface molybdenum sheet layers 122 have a sufficient molybdenum thermal conductivity 130 (see Figure 4), which is high, which allows the treated surface molybdenum sheet layers 122 to act as dissipation pathways. thermal energy 196 (see Figure 10) to thermal energy flow 194 to improve thermal shock resistance 190 of composite structure 104 (see Figure 4). In addition, the surface-treated molybdenum sheet layers 122 have a sufficient molybdenum melting point 132 (see Figure 4), which is very high, which allows the surface-treated molybdenum sheet layers 122 to act as barriers thermal penetration 198 (see Figure 10) that further enhance the thermal shock resistance 190 of the composite structure 104. Using the treated surface molybdenum sheet layers 122 as replacement layers in the composite structure 104, the shock resistance enhanced thermal 190 is achieved due to the very high molybdenum melting point 132 (see Figure 4) and the high molybdenum thermal conductivity 130 (see Figure 4) of the treated surface molybdenum sheet layers 122. The sheet layers surface-treated molybdenum materials 122 provide significant thermal penetration barriers 198 for thermal shock 190 or penetration of composite structure 104 due to dust high molybdenum fusion value 132 (see Figure 4) and high molybdenum thermal conductivity 130 (see Figure 4) that provide thermal energy input dissipation 192 (see Figure 10) when applied to a localized area.
[00177] As shown in Figure 10, each molybdenum composite hybrid laminate 100 for improving thermal shock resistance 190 comprises a plurality of layers of composite material 106 (see Figure 10) and each layer of composite material 106 comprises a reinforced polymeric material with fiber 108 (see Figure 4). Preferably, the layer of composite material 106 comprises a layer of material based on graphite / resin 164. The hybrid composite laminate of molybdenum 100 further comprises a plurality of layers of treated surface molybdenum sheet 122 interlaced between the layers of composite material 106 The surface-treated molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage fiber tensile strength 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of the fibers outside the geometric axis 110 (see Figure 4) in adjacent composite material layers 106 through Poisson effects in the treated surface molybdenum sheet layers 122. As shown in Figure 10, the molybdenum composite hybrid laminate 100 further comprises a plurality of adhesive layers 134 (see Figure 10) arranged between and connecting the adjacent layers of the mat layers composite material 106 and the surface treated molybdenum sheet layers 122. Adhesive layers 134 (see Figure 10) can act as electrical insulation layers 166 (see Figure 10) for the surface treated molybdenum sheet layers 122. The molybdenum composite hybrid laminate 100 is preferably used in a composite structure 104 (see Figure 4), such as, for example, an aircraft structure 10 (see Figure 1) and improves the thermal shock resistance 190 of composite structure 104.
[00178] In another embodiment of the description, a 490 method of improving thermal shock resistance 190 (see Figure 10) of a composite structure 104 using the layers of molybdenum sheet 122 (see Figure 10) is provided. Figure 24 is a flow chart illustrating one of the exemplary modalities of method 490 for improving thermal shock resistance 190 (see Figure 10) of composite structure 104. Method 490 comprises step 492 of treating a surface 125a or 125b of each one of a plurality of layers of molybdenum sheet 122 (see Figure 10). The surface treatment 125a or 125b of the molybdenum foil layers 122 may comprise one or more surface treatments comprising surface sol gel treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing , abrasion, laser ablation, chemical cleaning, chemical corrosion engraving or other suitable surface treatment.
[00179] Method 490 further comprises step 494 of interweaving the treated surface molybdenum sheet layers 122 with a plurality of layers of composite material 106 (see Figure 10). The molybdenum sheet layers 122 act as thermal penetration barriers 198 (see Figure 10) and thermal energy dissipation paths 196 (see Figure 10) that improve thermal shock resistance 190 (strength of a composite structure). The molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage a fiber tensile strength 116 (see Figure 4) and a fiber stiffness 118 (see Figure 4) of fibers outside the geometric axis 110 (see Figure 4) in adjacent composite material layers 106 through Poisson effects in the molybdenum foil layers 122. The molybdenum sheet layers 122 additionally have a sufficient molybdenum melting point 132 (see Figure 4) and a sufficient molybdenum thermal conductivity 130 (see Figure 4) to allow the molybdenum sheet layers 122 to act as thermal penetration barriers 198 (see Figure 10) and thermal energy dissipation paths 196 (see Figure 10) improve shock resistance thermal 190 (see Figure 10) of composite structure 104 (see Figure 4).
[00180] Method 490 further comprises step 496 of bonding to an adhesive layer 134 (see Figure 10) each of the layers of surface-treated molybdenum sheet 122 to adjacent layers of composite material 106 to form a composite molybdenum hybrid laminate 100 (see Figure 10) that has an improved conventional yield limit 102 (see Figure 4). The interlacing step 494 and the connecting step 496 may further comprise one or more compacting, consolidation and curing of the treated surface molybdenum sheet layers 122 and the interlaced composite material layers 106. Method 490 further comprises step 498 of using the hybrid molybdenum composite laminate 100 on composite structure 104 to improve the thermal shock resistance 190 of composite structure 104.
[00181] In another embodiment of the description, a composite molybdenum hybrid laminate 100 (see Figure 11) is provided to improve the impact durability 200 (see Figure 11) of a composite structure 104 (see Figure 4). Figure 11 is an illustration of a schematic diagram of another embodiment of a hybrid molybdenum composite laminate 100 of the description in which the treated surface molybdenum sheet layers 122 act as load dissipation paths 206 (see Figure 11) for improved 200 impact durability. The surface-treated molybdenum sheet layers 122 have a sufficiently high molybdenum stiffness 124 and a sufficient molybdenum resistance 126 that allows the surface-treated molybdenum sheet layers 122 to move the load 204 away from an impact point 202 through an impact source 200, such as, for example, hail collisions or bird collisions, thereby dulling the concentrated impact force. The surface-treated molybdenum sheet layers 122 spread the charge 204 over a larger area along the surface-treated molybdenum sheet layers 122 which improves the durability and impact resistance of the composite structure 104. The layers of composite material 106 (see Figure 11) are spared the load transfer 204 deeply in the molybdenum 100 composite hybrid laminate, thereby reducing the damaging effects associated with the point of impact 202. The use of high-surface molybdenum sheet layers 122 rigidity and high strength allows for thinner calibrators while also adding such benefits as improved lightning resistance and improved structural performance.
[00182] As shown in Figure 11, each molybdenum composite hybrid laminate 100 for improving impact durability 200 comprises a plurality of layers of composite material 106 and each layer of composite material 106 comprises a fiber-reinforced polymeric material 108 (see Figure 4). Preferably, the composite material layer 106 comprises a layer of material based on graphite / resin 164. The hybrid molybdenum composite laminate 100 further comprises a plurality of surface-treated molybdenum sheet layers 122 (see Figure 11) interlaced between the layers of composite material 106. The surface-treated molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage fiber tensile strength 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of the fibers outside the geometrical axis 110 (see Figure 4) in adjacent composite material layers 106 through Poisson effects in the surface treated molybdenum sheet layers 122. The surface treated molybdenum sheet layers 122 have additionally sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum resistance 126 (see Figure 4) to p allow the treated surface molybdenum sheet layers 122 to move the load 204 (see Figure 11) from the impact point 202 (see Figure 11), which improves impact durability 200. The molybdenum composite hybrid laminate 100 further comprises a plurality of adhesive layers 134 (see Figure 11) arranged between and connecting the adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122. The adhesive layers 134 (see Figure 11) can act as layers of insulation 166 (see Figure 11) for the surface-treated molybdenum foil layers 122. The composite molybdenum hybrid laminate 100 is preferably used in a composite structure 104 (see Figure 4), such as an aircraft structure 10 (see Figure 1) and improves the durability to impact of the composite structure 104.
[00183] In another embodiment, a method 530 for improving impact durability 200 (see Figure 11) of a composite structure 104 (see Figure 4) using layers of molybdenum sheet 122 is provided. Figure 26 is a flow chart which illustrates one of the exemplary modalities of the 530 method of improving impact durability. Method 530 comprises step 532 of treating a surface 125a or 125b (see Figure 6) of each of a plurality of layers of molybdenum sheet 122 (see Figure 11). The surface treatment 125a or 125b of the molybdenum foil layers 122 may comprise one or more surface treatments comprising surface sol gel treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing , abrasion, laser ablation, chemical cleaning, chemical corrosion engraving or other suitable surface treatment.
[00184] Method 530 further comprises step 534 of interweaving the treated surface molybdenum sheet layers 122 with a plurality of layers of composite material 106 (see Figure 11). The layers of molybdenum sheet 122 act as load dissipation paths 206 (see Figure 11) that improve impact durability at an impact point 202 of an impact source 200, such as hail collisions, bird or another source of impact. The layers of molybdenum sheet 122 preferably improve the resistance to impact damage 200 as, for example, from hail collisions and bird collisions. The molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage a fiber tensile strength 116 (see Figure 4) and a fiber stiffness 118 (see Figure 4) of fibers outside the geometric axis 110 (see Figure 4) in adjacent composite material layers 106 through Poisson effects in the molybdenum foil layers 122. The molybdenum sheet layers 122 additionally have sufficient molybdenum stiffness 124 (see Figure 4) and a tensile strength. sufficient molybdenum 126 (see Figure 4) to allow the molybdenum sheet layers 122 to act as load dissipation paths 206 (see Figure 11) that improve the impact durability of composite structure 104.
[00185] Method 530 further comprises step 536 of bonding to an adhesive layer 134 (see Figure 11) each of the layers of surface-treated molybdenum sheet 122 to adjacent layers of composite material 106 to form a composite molybdenum hybrid laminate 100 (see Figure 11) which has an improved conventional yield limit 102 (see Figure 4). The interlacing step 534 and the connecting step 536 may additionally comprise one or more compacting, consolidating and curing of the treated surface molybdenum sheet layers 122 and the interlaced composite material layers 106. Method 530 further comprises step 538 of using molybdenum composite hybrid laminate 100 on composite structure 104 to improve the impact durability of composite structure 104. Composite structure 104 preferably comprises an aircraft structure 10 (see Figure 10).
[00186] In another embodiment of the description, a composite molybdenum hybrid laminate 100 is provided to direct the load 214 (see Figure 12A) through main load paths 212a and secondary load paths 212b (see Figure 12A) at a composite structure 104 (see Figure 12A). Figure 12A is a schematic diagram illustration of another embodiment of a hybrid molybdenum composite laminate 100 of the description showing the surface treated molybdenum sheet layers 122 and the composite material layer 106 of the composite structure 104 that direct load 214 around a non-load bearing area 210, such as, for example, access holes, access panels, system penetrations and other design artifacts. Figure 12A shows the non-load bearing area 210 with a system penetrating element 211. Figure 12B is an illustration of a schematic diagram of a cross-section taken on lines 12B-12B of Figure 12A. Figure 12B shows the non-load bearing area 210 with the system penetrating element 211, the composite material layer 106 of the composite structure 104, and the treated surface molybdenum sheet layers 122 that act as load routing paths. 215. When non-load bearing areas 210, such as access holes, system penetrations or other suitable design artifacts, are required in composite structures, it is necessary to increase the stacking damping of composite structure 104 to facilitate the load flow 214 around these non-load bearing areas 210. The surface-treated molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) which is high and sufficient molybdenum resistance 126 (see Figure 4) which is high to allow the treated surface molybdenum sheet layers 122 to direct the load 214 in directional pathways arga 215 (see Figure 12B) around the non-load bearing area 210 in composite structure 104. The treated surface molybdenum sheet layers 122 have very high molybdenum stiffness 124 (see Figure 4) and a molybdenum resistance very high 126 (see Figure 4) and will extract the load 214 and reinforce the non-load bearing areas 210, such as access holes, system penetrations and other design artifacts, without the need to add additional thickness to the composite structure 104. The surface-treated molybdenum sheet layers 122 allow cargo 214 to travel on effective, slim and personalized load-steering paths 215. Efficiency can provide ideal advantages regarding the cost, part volume and weight of the composite structure 104.
[00187] Each molybdenum composite hybrid laminate 100 for directing the load 214 around the non-load bearing areas 210 in the composite structure 104 comprises a plurality of layers of composite material 106 and each layer of composite material 106 comprises a reinforced polymeric material with fiber 108 (see Figure 4). Preferably, the composite material layer 106 comprises a graphite / resin based material layer. The hybrid molybdenum composite laminate 100 further comprises a plurality of surface-treated molybdenum sheet layers 122 interlaced between the layers of composite material 106. The surface-treated molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage the tensile strength of fiber 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of fibers outside the geometry axis 110 (see Figure 4) in adjacent composite material layers 106 through effects of Poisson in the surface-treated molybdenum sheet layers 122. The surface-treated molybdenum sheet layers 122 additionally have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum resistance 126 (see Figure 4) to allow the surface-treated molybdenum sheet layers 122 to direct the load 214 along the load routing paths 21 5 around the 210 non-load bearing areas (see Figure 12A). The molybdenum composite hybrid laminate 100 further comprises a plurality of adhesive layers 134 disposed between and connecting the adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122. The molybdenum composite hybrid laminate 100 is preferably used in a composite structure 104 (see Figure 4), such as, for example, an aircraft structure 10 (see Figure 1), and directs cargo 214 around non-load bearing areas 210 in composite structure 104.
[00188] In another embodiment of the description, a method 550 of directing load 214 (see Figure 12A) is provided around the non-load bearing areas 210 (see Figure 12A) in a composite structure 104 (see Figure 4) that uses molybdenum foil layers 122. Figure 27 is a flowchart illustrating one of the exemplary modalities of method 550 of directing load 214 around non-load bearing areas 210. Non-load bearing areas 210 may comprise holes access panels, access panels, system penetrations or other suitable design artifacts. Method 550 comprises step 552 of treating a surface 125a or 125b (see Figure 6) of each of a plurality of layers of molybdenum sheet 122 (see Figure 12A). The surface treatment 125a or 125b of the molybdenum foil layers 122 may comprise one or more surface treatments comprising surface sol gel treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing , abrasion, laser ablation, chemical cleaning, chemical corrosion engraving or other suitable surface treatment.
[00189] Method 550 further comprises step 554 of interlacing the treated surface molybdenum sheet layers 122 (see Figure 12A) with a plurality of layers of composite material 106. The molybdenum sheet layers 122 act as targeting paths load 215 (see Figures 12A to B) that direct load 214 around non-load bearing areas 210 in composite structure 104. Molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage a fiber tensile strength 116 (see Figure 4) and a fiber stiffness 118 (see Figure 4) of fibers outside the geometric axis 110 (see Figure 4) in adjacent composite material layers 106 through Poisson effects in the layers of molybdenum sheet 122. Molybdenum sheet layers 122 additionally have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum strength 126 (see Figure 4) to allow the layers of molybdenum sheet 122 to act as load steering paths 215 that direct load 214 around non-load bearing areas 210 in composite structure 104.
[00190] Method 550 further comprises step 556 of bonding to an adhesive layer 134 (see Figure 4) each of the layers of surface-treated molybdenum sheet 122 to adjacent layers of composite material 106 to form a composite molybdenum hybrid laminate 100 (see Figure 12 um) that has an improved conventional yield limit 102 (see Figure 4). The interlacing step 554 and the connecting step 556 can additionally comprise one or more compaction, consolidation and curing of the treated surface molybdenum sheet layers 122 and the interlaced composite material layers 106. Method 550 further comprises step 558 of using the hybrid molybdenum composite laminate 100 on composite structure 104 to direct load 214 around non-load bearing areas 210 on composite structure 104.
[00191] In another embodiment of the description, a composite molybdenum hybrid laminate 100 is provided to improve a curing cycle, such as to improve the curing cycle characteristics of a composite structure 104 (see Figure 13) . Figure 13 is an illustration of a schematic diagram of another embodiment of a hybrid molybdenum composite laminate 100 of the description in which the treated surface molybdenum sheet layers 122 act as thermal and temperature controllers 226 for improved curing cycle. , such as improved curing cycle characteristics. Thermal and temperature uniformity and the ability to control excessive thermal energy due to the kinetic curing of resins can be important manufacturing problems when curing thermoset composites. Figure 13 shows the excess thermal energy 222 that is generated in a cure area 220 as the cure in the cure area 220 advances at a faster speed. Excess thermal energy 222 is carried away quickly along the thermal energy flow paths 224, thereby reducing the risk of thermal overshoot. The surface-treated molybdenum sheet layers 122 have sufficient molybdenum thermal conductivity 130 (see Figure 4) that is high to allow the surface-treated molybdenum sheet layers 122 to act as thermal and temperature controllers 226 that improve the cycle of curing, such as improving the curing cycle characteristics of the composite structure 104 (see Figure 4). The curing cycle characteristics can comprise a curing cycle extension, a curing cycle thermal leveling, a curing cycle temperature leveling, a curing cycle thermal control, a curing cycle temperature control or a another suitable curing cycle feature.
[00192] The high thermal conductivity of molybdenum 130 (see Figure 4) allows the treated surface molybdenum sheet layers 122 to perform structurally well while helping to control or level the thermal and temperature uniformity for the improved curing cycle, such as improved curing cycle characteristics. The surface-treated molybdenum sheet layers 122 can improve the overall curing cycle length and thermal strength due to their excellent thermal conductivity of molybdenum 130 (see Figure 4), thereby reducing overall manufacturing costs. The excellent thermal conductivity of molybdenum 130 (see Figure 4) provides improved thermal and temperature control or leveling in composite structure 104 (see Figure 4) and allows for more robust manufacturing processing cycles. The curing and structurally advantageous characteristics of the surface treated molybdenum sheet layers 122 (see Figure 13) can be adapted to provide an optimal solution.
[00193] As shown in Figure 13, each molybdenum composite hybrid laminate 100 comprises a plurality of layers of composite material 106 and each layer of composite material 106 comprises a fiber-reinforced polymeric material 108 (see Figure 4). Preferably, the composite material layer 106 comprises a graphite / resin based material layer. As shown in Figure 13, the molybdenum composite hybrid laminate 100 further comprises a plurality of surface-treated molybdenum sheet layers 122 interlaced between the layers of composite material 106. The surface-treated molybdenum sheet layers 122 have a stiffness of Sufficient molybdenum 124 (see Figure 4) to leverage fiber tensile strength 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of fibers outside the 110 axis (see Figure 4) in layers of composite material adjacent 106 through Poisson effects on the surface treated molybdenum sheet layers 122. The surface treated molybdenum sheet layers 122 additionally have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum resistance 126 (see Figure 4) to allow the treated surface molybdenum sheet layers 122 to act as thermal and temperature 226 that improve a curing cycle, such as improving curing cycle characteristics, of composite structure 104. The composite molybdenum hybrid laminate 100 further comprises a plurality of adhesive layers 134 (see Figure 13) arranged between and that connect the adjacent layers of the composite material layers 106 and the surface-treated molybdenum sheet layers 122. Adhesive layers 134 (see Figure 13) can act as the insulating layers 166 (see Figure 13) for the sheet layers surface-treated molybdenum 122. The composite molybdenum hybrid laminate 100 is preferably used in a composite structure 104 (see Figure 4), such as, for example, an aircraft structure 10 (see Figure 1).
[00194] In another embodiment of the description, a method 510 of improving a curing cycle of a composite structure 104 (see Figure 4) using molybdenum foil layers 122 (see Figure 13) is provided. Figure 25 is a flow chart illustrating one of the exemplary modalities of method 510 of improving the curing cycle. Method 510 comprises step 512 of treating a surface 125a or 125b (see Figure 6) of each of a plurality of layers of molybdenum sheet 122. Treatment of surface 125a or 125b of layers of molybdenum sheet 122 may comprise one or more surface treatments comprising surface gel sol treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning, chemical etching or a other suitable surface treatment.
[00195] Method 510 further comprises step 514 of interweaving the treated surface molybdenum sheet layers 122 with a plurality of layers of composite material 106 (see Figure 13). The molybdenum sheet layers 122 act as thermal and temperature controllers 224 (see Figure 13) that improve the curing cycle of a composite structure 104 (see Figure 4). The molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage a fiber tensile strength 116 (see Figure 4) and a fiber stiffness 118 (see Figure 4) of fibers outside the geometric axis 110 (see Figure 4) on adjacent composite material layers 122 through Poisson effects on the molybdenum sheet layers 122. The molybdenum sheet layers 122 additionally have sufficient molybdenum thermal conductivity 130 (see Figure 4) to allow for the layers of molybdenum sheet 122 act as thermal and temperature controllers 226 (see Figure 13) that improve the curing cycle of composite structure 104 (see Figure 4). The molybdenum sheet layers 122 act as thermal and temperature controllers 226 to improve the curing cycle, such as, for example, improving curing cycle characteristics that comprise a curing cycle extension, a curing cycle thermal leveling, a cure cycle temperature leveling, a cure cycle thermal control, a cure cycle temperature control or another suitable cure cycle feature.
[00196] Method 510 further comprises step 516 of bonding to an adhesive layer 134 (see Figure 13) each of the surface-treated molybdenum sheet layers 122 to the adjacent composite material layers 106 to form a composite molybdenum hybrid laminate 100 (see Figure 13) which has an improved conventional yield limit 102 (see Figure 4). The interlacing step 514 and the connecting step 516 can additionally comprise one or more of compacting, consolidating and curing the treated surface molybdenum sheet layers 122 and the interlaced composite material layers 106. Method 510 further comprises step 518 of using the molybdenum composite hybrid laminate 100 in composite structure 104 to improve the curing cycle of composite structure 104.
[00197] In other modalities of the description, hybrid composite laminates of molybdenum 100 are provided to extract the load 234 (see Figures 14A and 14C) through main load paths 232a and secondary load paths 232b (see Figures 14A and 14C) in a composite structure 104 (see Figures 14A and 14C) and to reinforce repair areas 230 (see Figures 14A and 14C), such as, for example, holes, weakened areas, damaged areas and other areas requiring repair, in a composite structure 104. Figure 14A is an illustration of a schematic diagram of another embodiment of a hybrid molybdenum composite laminate 100 of the description showing the surface treated molybdenum sheet layers 122 of the composite structure 104 reinforcing an area of patch repair 230a. For the purposes of this order, a patch repair means, a type of bonded repair in which the replaced material is inserted to fill a damaged area. Figure 14B is an illustration of a schematic diagram of a cross-section taken on lines 14B-14B of Figure 14A. Figure 14C is a schematic diagram illustration of another embodiment of a hybrid molybdenum composite laminate 100 of the description showing the surface-treated molybdenum sheet layers 122 of the composite part 104 that reinforces a chamfer repair area 230b . For the purposes of this order, a chamfer repair means a type of bonded repair in which a damaged area is sanded to produce a tapered effect and then the replaced material is placed over the damaged area. Figure 14D is an illustration of a schematic diagram of a cross-section taken on lines 14D-14D of Figure 14C.
[00198] Figures 14A to 14B show the treated surface molybdenum sheet layers 122 that act as load extraction paths 235 to move the load 234 (see Figure 14A) from the repair area 230, for example, the patch repair 230a and provide a reinforcing element 236 of repair area 230, for example, patch repair area 230a. Figures 14C to 14D show the treated surface molybdenum sheet layers 122 that act as load extraction paths 235 to move the load 234 (see Figure 14C) from the repair area 230, for example, the chamfer repair area 230b and provide a reinforcing element 236 of the repair area 230, for example, the chamfer repair area 230b. Using the surface-treated molybdenum sheet layers 122 as part of the composite structure 104, the surface-treated molybdenum sheet layers 122 allow the load 234 to travel on effective, thin and customized load extraction paths 235 (see Figures 14B and 14D). The high strength of molybdenum 126 (see Figure 4) and the high rigidity of molybdenum 124 (see Figure 4) of the surface-treated molybdenum sheet layers 122 allow for thinner and more customized load extraction paths 235 for more effective and more efficient repairs. thin, without needing to add significant additional thickness to the composite structure 104. In addition, the treated surface molybdenum sheet layers 122 that act as load extraction paths 235 to extract the load 234 and provide reinforcement elements 236 for the repair areas 230, such as patch repair areas (230a) and chamfer repair areas (230b), provide more effective and efficient repairs of composite structures 104, less aerodynamic drag for vehicles with such composite structures 104 and improved appearance of composite structures 104.
[00199] Each hybrid molybdenum composite laminate 100 to reinforce and spread the load 234 (Figures 14A and 14C) from a repair area 230 (Figures 14A to 14D) comprises a plurality of layers of composite material 106. Each layer of composite material 106 comprises a fiber-reinforced polymeric material 108 (see Figure 4). Preferably, the composite material layer 106 comprises a graphite / resin based material layer. The molybdenum composite hybrid laminate 100 further comprises a plurality of layers of surface-treated molybdenum sheet 122 interlaced between layers of composite material 106. As discussed above, the layers of surface-treated molybdenum sheet 122 have sufficient molybdenum stiffness. 124 (see Figure 4) to leverage the fiber tensile strength 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of the fibers outside the geometry axis 110 (see Figure 4) in adjacent composite material layers 106 through Poisson effects on the surface treated molybdenum sheet layers 122. The surface treated molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum resistance 126 (see Figure 4) to allow the surface-treated molybdenum sheet layers 122 to act as load extraction paths 235 (see Figures 14B and 14D) to move the load 234 away from a repair area 230 and provide reinforcement elements 236 for the repair areas 230 in the composite structure 104. The composite molybdenum hybrid laminate 100 additionally comprises a plurality of adhesive layers 134 arranged between and which connect the adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122. The hybrid molybdenum composite laminate 100 is preferably used in a composite structure 104 (see Figures 14A, 14C), such as example, an aircraft structure (see Figure 1) and reinforces the repair areas in the composite structure 104.
[00200] In another embodiment of the description, a method 570 of reinforcement and load spacing 234 (Figures 14A and 14C) of a repair area 230 (Figures 14A to 14D) is provided in a composite structure 104 using the layers of molybdenum sheet 122 (Figures 14A to 14D). Figure 28 is a flowchart illustrating one of the exemplary modalities of method 570 of load reinforcement and clearance 234 (FIGS. 14A and 14C) of repair area 230 (Figures 14A to 14D). The repair area 230 can comprise a patch repair area 230a (see Figures 14A to 14B), a chamfer repair area 230b (see Figures 14C to 14D), holes, weakened areas, damaged areas or another repair area .
[00201] Method 570 comprises step 572 of treating a surface 125a or 125b (see Figure 6) of each of a plurality of layers of molybdenum sheet 122. Treatment of surface 125a or 125b of layers of molybdenum sheet 122 may comprise one or more surface treatments comprising surface gel sol treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning, corrosion etching chemical or other suitable surface treatment.
[00202] Method 570 further comprises step 574 of interweaving the treated surface molybdenum sheet layers 122 with a plurality of layers of composite material 106. The molybdenum sheet layers 122 act as reinforcing elements 236 (Figures 14A to 14D) and load extraction paths 235 (Figures 14A to 14D) that reinforce and move load 234 (Figures 14A and 14C) from a repair area 230 (Figures 14A to 14D) in a composite structure 104. The sheet layers of molybdenum 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage a fiber tensile strength 116 (see Figure 4) and a fiber stiffness 118 (see Figure 4) of fibers outside the 110 geometry axis (see Figure 4) in layers of adjacent composite material 106 through Poisson effects in the layers of molybdenum foil 122. The layers of molybdenum foil 122 additionally have sufficient molybdenum stiffness 124 (see Figure 4) and a sufficient molybdenum resistance 126 (see Figure 4) to allow the molybdenum sheet layers 122 to reinforce and move the load 234 away from the repair area 230 in the composite structure 104.
[00203] Method 570 further comprises step 576 of bonding with an adhesive layer 134 (see Figure 4) of each of the surface-treated molybdenum sheet layers 122 to adjacent layers of composite material 106 to form a composite hybrid laminate molybdenum 100 (see Figures 14A to 14D) which has an improved conventional yield strength 102 (see Figure 4). Interlacing step 574 and bonding step 576 can further comprise one or more of compacting, consolidating and curing interlaced surface treated molybdenum sheet layers 122 and composite material layers 106. Method 570 additionally comprises step 578 of using the hybrid molybdenum composite laminate 10 on the composite structure 104 to reinforce and extract the load 534 from the repair area 230 on the composite structure 104.
[00204] In another embodiment of the description, a composite molybdenum hybrid laminate 100 (see Figure 18) is provided to mitigate or eliminate areas of 268 fiber distortion (see Figure 17) in a composite structure 104 that uses foil layers of molybdenum 122 (see Figure 18). Figure 17 is an illustration of a schematic diagram of a composite structure 104 that has fiber distortion areas 268. Figure 17 shows a pre-cured or cured composite structure 260 that has 262 fibers and that has a T-shaped configuration. and a non-uniform cross-section. Figure 17 further shows the pre-cured or cured composite structure 260 joined to a composite structure 104, such as an uncured composite structure 264 having fibers 266 and having a uniform cross-section. Where the pre-cured or cured composite structure 260 is joined to the uncured composite structure 264, differences in pressure between the pre-cured or cured composite structure 260 and the uncured composite structure 264 can produce the wrinkling of layers of composite material 106 and 266 fiber arc waves that can result in 268 fiber distortion areas (see Figure 17).
[00205] Figure 18 is an illustration of a schematic diagram of another among the modalities of a hybrid composite laminate of molybdenum 100 of the description where the layers of molybdenum sheet 122 act as fiber stabilizers 270 to mitigate or eliminate the areas of distortion 268 fiber (see Figure 17). Figure 18 shows the pre-cured or cured composite structure 260 which has fibers 262 and which has a T-shaped configuration and a non-uniform cross-section. Figure 18 further shows the pre-cured or cured composite structure 260 joined to composite structure 104, such as an uncured composite structure 264 having fibers 266 and having a uniform cross-section. In this embodiment, the surface treated molybdenum sheet layers 122 (see Figure 18) can be added to the uncured composite structure 264 where the precured or cured composite structure 260 is joined to the uncured composite structure 264. surface-treated molybdenum sheet 122 have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum resistance 126 (see Figure 4) to allow the surface-treated molybdenum sheet layers 122 (see Figure 18 ) to act as fiber stabilizers 270 (see Figure 18) that mitigate or eliminate fiber distortion 268 (see Figure 17) in composite structure 104 (see Figure 18), as well as uncured composite structure 264 and that results on stabilized fibers 272 (see Figure 18) on composite structure 104. In particular, the additional molybdenum stiffness 124 mitigates or eliminates 266 fiber arc waves (see Figure 17) , which in turn mitigates or eliminates 268 fiber distortion areas (see Figure 17). In addition, the surface treated molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage fiber tensile strength 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of fibers outside the geometric axis 110 (see Figure 4) in adjacent composite material layers 106 (see Figure 18) through Poisson effects in the treated surface molybdenum sheet layers 122.
[00206] Each molybdenum composite hybrid laminate 100 (see Figure 18) comprises a plurality of layers of composite material 106 (see Figure 18) and each layer of composite material 106 comprises a fiber-reinforced polymeric material 108 (see Figure 4). Preferably, the composite material layer 106 comprises a graphite / resin based material layer. The molybdenum composite hybrid laminate 100 further comprises one or more layers of surface-treated molybdenum sheet 122 interlaced between the layers of composite material 106. The molybdenum composite hybrid laminate 100 further comprises one or more adhesive layers 134 (see Figure 18 ) arranged between and connecting adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122. The hybrid molybdenum composite laminate 100 can be used in a composite structure 104 and mitigates or eliminates areas of fiber distortion 268 in composite structure 104.
[00207] In another embodiment, a method 600 is provided to mitigate a fiber distortion in a composite structure 104 that uses layers of molybdenum sheet 122. Figure 29 is a flowchart that illustrates one of the exemplary modalities of method 600 to mitigate a fiber distortion. Method 600 comprises step 602 of treating a surface 125a or 125b (see Figure 6) of each of a plurality of layers of molybdenum sheet 122. Treatment of surface 125a or 125b of layers of molybdenum sheet 122 can comprise one or more surface treatments comprising surface gel sol treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing, abrasion, laser ablation, chemical cleaning, chemical etching or other suitable surface treatment.
[00208] Method 600 further comprises step 604 of interweaving the treated surface molybdenum sheet layers 122 with a plurality of layers of composite material 106. The molybdenum sheet layers 122 act as fiber stabilizers 270 (see Figure 18) that mitigate fiber distortion 268 (see Figure 17) in a composite structure 104. Molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 to leverage fiber tensile strength 116 and fiber stiffness 118 of fibers outside the geometrical axis 110 in adjacent composite material layers 106 through Poisson effects in the molybdenum sheet layers 122. The molybdenum sheet layers 122 additionally have sufficient molybdenum stiffness 124 and sufficient molybdenum resistance 126 to allow to the molybdenum sheet layers 122 to act as fiber stabilizers 270 that mitigate 268 fiber distortion in the composite structure. ta 104.
[00209] Method 600 further comprises step 606 of bonding with an adhesive layer 134 of each of the surface treated molybdenum sheet layers 122 to adjacent layers of composite material 106 to form a molybdenum composite hybrid laminate 100 (see Figure 18) which has an improved conventional yield strength 102 (see Figure 4). The interlacing step 604 and the connecting step 606 can additionally comprise one or more of compacting, consolidating and curing the interlaced surface treated molybdenum sheet layers 122 and the composite material layers 106. Method 600 further comprises step 608 of use of the molybdenum composite hybrid laminate 100 in the composite structure 104 to mitigate a fiber distortion 268 in the composite structure 104.
[00210] Figure 19 is a flowchart illustrating one of the exemplary modalities of a method 300 of forming a hybrid composite laminate of molybdenum 100 (see Figure 4) or a stack of molybdenum laminate 101 or 150 (see Figures 5 to 6). Method 300 comprises step 302 of surface treatment 125a or 125b (see Figure 6) of each of a plurality of layers of molybdenum sheet 122 or of each of a plurality of sheets of molybdenum 123 (see Figure 6 ). The layer of molybdenum sheet 122 or molybdenum sheet 123 is preferably surface treated to improve the bond between the layer of molybdenum sheet 122 or sheet of molybdenum 123 and an adjacent composite material layer 106 (see Figure 4). The surface 125 a or 125b of the layer of molybdenum sheet 122 or molybdenum sheet 123 can be treated with a surface treatment process comprising surface gel sol treatment, water based sol gel paint, abrasive blasting, sanding, blasting sanding, solvent scrubbing, abrasion, laser ablation, chemical cleaning, chemical etching or other suitable surface treatment process.
[00211] Method 300 further comprises step 304 of interweaving the treated surface molybdenum sheet layers 122 with a plurality of layers of composite material 106. Preferably, each layer of composite material 106 comprises a fiber-reinforced polymeric material 108 ( see Figures 4, 5). Preferably, the composite material layer 106 comprises a graphite / resin based material layer. The surface-treated molybdenum sheet layers 122 leverage the tensile strength of fiber 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of fibers outside the geometry axis 110 (see Figure 4) in adjacent layers of composite material 106 through Poisson effects on the surface-treated molybdenum sheet layers 122. In a mode with the stacking of molybdenum laminate 101 (see Figure 5), two or more of the layers of composite material 106 can each have a cutout portion 144 (see Figure 5) comprising a surface-treated molybdenum sheet 123 and for this method, method 300 may additionally comprise internal scaling edges 148 (see Figure 5) of the portions cutout 144 to avoid overlapping two or more inner edges 148 to provide improved load distribution by molybdenum sheet 123.
[00212] Method 300 further comprises step 306 of bonding with an adhesive layer 134 (see Figure 4) each of the layers of surface-treated molybdenum sheet 122 to adjacent composite material layers 106 to form the composite hybrid laminate of molybdenum 100 which has an improved conventional yield strength 102 (see Figure 4). In an embodiment with molybdenum laminate stacking 101 (see Figure 5), method 300 may additionally comprise a bond with an adhesive layer 134 of each of the surface-treated molybdenum sheets 123 of the layers containing molybdenum sheet 146 to adjacent composite material layers 106 to form the molybdenum laminate stacking 101. The interlacing step 304 and / or bonding step 306 of method 300 may further comprise one or more of compacting, consolidating and curing the sheet layers. intertwined treated surface molybdenum 122 or molybdenum sheets 123 and layers of composite material 106. For example, consolidation and curing can be carried out through autoclave processing, vacuum bag processing or other known process. Autoclave processing involves the use of an autoclave pressure vessel that provides curing conditions for a composite material and the application of vacuum, pressure, heating rate and curing temperature can be controlled.
[00213] Method 300 further comprises step 308 of using the molybdenum 100 composite hybrid laminate or stacking molybdenum laminate 101 or 150 in a composite structure 104 (see Figure 4) such as an aircraft structure 10 (see Figure 1).
[00214] In another embodiment, method 300 may further comprise, after using the molybdenum composite hybrid laminate 100 in a composite structure 104, coupling the molybdenum composite hybrid laminate 100 to one or more 168 electrical sensor devices (see Figure 16) to guide electrical current 170 (see Figure 16) through the layers of molybdenum sheet 122, while monitoring any changes in the flow of electrical current 170 through the layers of molybdenum sheet 122 and obtain structural health data 254 ( see Figure 16) of composite structure 104.
[00215] As discussed in detail above, in one embodiment, the surface-treated molybdenum sheet layers 122 used in method 300 may have a sufficient molybdenum electrical conductivity 128 (see Figure 4) to allow the molybdenum sheet layers surface treated 122 to act as an electric bus 160 (see Figure 16) in an aircraft structure 10, which results in a reduced overall weight of the aircraft structure 10 (see Figure 1). As discussed in detail above, in another embodiment, the surface-treated molybdenum sheet layers 122 used in method 300 may have sufficient molybdenum strength 126 (see Figure 4), sufficient molybdenum stiffness 124 (see Figure 4 ) and sufficient molybdenum electrical conductivity 128 (see Figure 4) to allow the molybdenum sheet layers 122 to act as an aircraft keel beam 240 (see Figure 15) and current return path 242 that disperses the electric current 184 (see Figure 15) from a radius drop 180 (see Figure 15) to a composite structure 104 (see Figure 4), such as an aircraft structure 10 (see Figure 1).
[00216] As discussed in detail above, in another embodiment, the surface-treated molybdenum sheet layers 122 used in method 300 may have sufficient molybdenum electrical conductivity 128 (see Figure 4) and sufficient molybdenum thermal conductivity 130 (see Figure 4) to allow layers of molybdenum sheet 122 to act as electrical energy dissipation paths 186 (see Figure 9) that improve the radius drop attenuation 180 (see Figure 9) of a composite structure 104 (see Figure 4). As discussed in detail above, in another embodiment, the surface-treated molybdenum sheet layers 122 used in method 300 may have a sufficient molybdenum melting point 132 (see Figure 4) and a sufficient molybdenum thermal conductivity 130 (see Figure 4) that allows the molybdenum sheet layers 122 to act as thermal penetration barriers 198 and thermal energy dissipation paths 196 (see Figure 10) that improves the thermal shock resistance of composite structure 104 (see Figure 4).
[00217] As discussed in detail above in another embodiment, the surface treated molybdenum sheet layers 122 used in method 300 may have a sufficient molybdenum thermal conductivity 130 (see Figure 4) to allow the molybdenum sheet layers 122 to act as thermal and temperature controllers 226 (see Figure 13) that improve a cure cycle, such as improving the cure cycle characteristics of composite structure 104 (see Figure 4).
[00218] As discussed in detail above in another embodiment, the surface-treated molybdenum sheet layers 122 used in method 300 may have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum strength 126 (see Figure 4) to allow the molybdenum sheet layers 122 to act as load dissipation paths 206 (see Figure 11) that improve the impact durability of composite structure 104 (see Figure 4).
[00219] As discussed in detail above in another embodiment, the surface-treated molybdenum sheet layers 122 used in method 300 may have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum resistance 126 (see Figure 4) to allow the molybdenum sheet layers 122 to act as load direction trajectories 215 (see Figures 12A to 12B) to direct load 214 (see Figures 12A to 12B) around non-load bearing areas 210 (see Figures 12A to 12B) on composite structure 104 (see Figures 12A-12b). As discussed in detail above, in another embodiment, the surface-treated molybdenum sheet layers 122 used in method 300 may have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum strength 126 (see Figure 4 ) to allow the molybdenum sheet layers 122 to act as reinforcement elements 236 (see Figures 14A to 14B) and load extraction paths 235 (see Figures 14A-14B) that reinforce and extract load 234 (see Figure 14A) out of a repair area 230 (see Figures 14A-14B) on composite structure 104 (see Figures 14A to 14B). As discussed in detail above, in another embodiment, the surface-treated molybdenum sheet layers 122 used in method 300 may have sufficient molybdenum stiffness 124 (see Figure 4) and sufficient molybdenum strength 126 (see Figure 4 ) to allow the molybdenum sheet layers 122 to act as fiber stabilizers 270 (see Figure 18) between a cured composite structure 262 (see Figure 18) and an uncured composite structure 264 (see Figure 18).
[00220] Method 300 is a method of forming the composite molybdenum hybrid laminate 100 or stacking molybdenum laminate 101 described in this document. However, molybdenum composite hybrid laminate 100 or molybdenum laminate stacking 101 can be produced by any of a number of methods. In the case of thermoplastic composites, it is preferred that laminates are prepared by successively placing long continuous strips of fibrous tapes pre-impregnated with thermoplastic resin ("prepregs") by means of a thermoplastic application head directly on the treated outer surface of a leaf. By placing strips of tape side by side while consolidating them by applying heat and pressure, a continuous composite substrate with fibers oriented in parallel is produced. After that, other substrates or composite substrates can be placed on top of the first substrate, which depends on the required properties of the laminate. The substrates or substrates are part of a composite layer. Then, a sheet layer is laminated over the consolidated composite layer and is bonded, for example, heat-fused, to the composite. After that, a next layer of organic composite is formed on top of the metal sheet by placing a substrate or substrates as described above. Finally, after placing the predetermined number of layers of metallic foil and organic polymeric matrix, an outer layer of metallic foil is applied. The outer layers of foil protect the underlying organic composite of hybrid laminates from the environment and attack by fluids. Alternative methods of manufacture are also useful. For example, all layers of the hybrid laminate can be stacked in an autoclave or press, without pre-melting layers and can then be melted under heat and pressure applied to a single laminate.
[00221] Figure 20 is a flow chart illustrating another of the exemplary modalities of a method 400 for monitoring the structural health of a composite structure 104 (see Figure 4) such as an aircraft structure 10 (see Figure 1) that uses layers of molybdenum sheet 122 (see Figure 4). Method 400 comprises step 402 of treating a surface 125a or 125b (see Figure 6) of each of a plurality of layers of molybdenum sheet 122. The layer of molybdenum sheet 122 is treated on the surface to improve bonding between the molybdenum sheet layer 122 and an adjacent composite material layer 106 (see Figure 4). The surface 125a or 125b of the molybdenum sheet layer 122 can be treated with a surface treatment process comprising surface gel treatment, water based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing , abrasion, laser ablation, chemical cleaning, chemical corrosion etching or other suitable surface treatment process.
[00222] Method 300 further comprises step 404 of interweaving the surface-treated molybdenum sheet layers 122 with a plurality of layers of composite material 106. Preferably, each layer of composite material 106 comprises a fiber-reinforced polymeric material 108 ( see Figures 4, 5). The surface-treated molybdenum sheet layers 122 have sufficient molybdenum stiffness 124 (see Figure 4) to leverage fiber tensile strength 116 (see Figure 4) and fiber stiffness 118 (see Figure 4) of the fibers outside the geometric axis 110 (see Figure 4) in adjacent composite material layers 106 through Poisson effects in the surface treated molybdenum sheet layers 122. The surface treated molybdenum sheet layers 122 are preferably separated between themselves and have sufficient molybdenum electrical conductivity 128 (see Figure 4) to allow the surface-treated molybdenum sheet layers 122 to act as an electrical bus 160 (see Figure 16). The hybrid molybdenum composite laminate 100 further comprises a plurality of adhesive layers 134 disposed between and joining adjacent layers of the composite material layers 106 and the treated surface molybdenum sheet layers 122.
[00223] Method 400 further comprises step 406 of bonding with an adhesive layer 134 (see Figure 16) of each of the surface-treated molybdenum sheet layers 122 to adjacent layers of composite material 106 to form the composite hybrid laminate molybdenum 100 which has an improved conventional yield strength 102 (see Figure 4). Interlacing step 404 and / or bonding step 406 of method 400 may further comprise one or more of compacting, consolidating and curing interlaced surface treated molybdenum sheet layers 122 and layers of composite material 106. For example, consolidation and curing can be carried out through autoclave processing or another known process.
[00224] Method 400 additionally comprises step 408 of coupling one or more electrical sensor devices 168 (see Figure 16) to one or more composite molybdenum hybrid laminates 100. Method 400 additionally comprises step 410 of directing current electrical 170 (see Figure 16) through the surface-treated molybdenum sheet layers 122 with one or more electrical sensor devices 168. Method 400 additionally comprises step 412 of monitoring any change in electrical current flow 172 ( see Figure 16) through the surface-treated molybdenum sheet layers 122 with one or more electrical sensor devices 168. Method 400 additionally comprises step 414 of obtaining structural health data 254 (see Figure 16) of the structure composite 104 through one or more signals 252 (see Figure 16) of one or more electrical sensor devices 168. Structural health data 254 can understand one or more of lightning strike detection, initiation of structural failures, propagation of structural failures, potential deterioration, actual deterioration, structural health data detected through total or partial electrical current interruption or other appropriate structural health data.
[00225] Many modifications and other modalities of the description will come to the mind of a person skilled in the art to which this description belongs who have the benefit of the teachings presented in the above descriptions and in the associated drawings. The modalities described in this document are to be considered illustrative and are not intended to be limiting or complete. Although specific terms are used in this document, they are used in a descriptive and generic sense and not for the purpose of limitation.

权利要求:
Claims (7)
[0001]
1. Molybdenum composite hybrid laminate (100) characterized by the fact that it comprises: a plurality of layers of composite material (106); a plurality of surface treated molybdenum sheet layers (122) interlaced between the composite material layers (106), wherein the molybdenum sheet layer (122) has a surface treated by means of one or more surface treatments selected from from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting, sanding, sandblasting, solvent scrubbing, abrasion, chemical cleaning, laser ablation and chemical corrosion engraving; and a plurality of adhesive layers (134) arranged between and connecting adjacent layers of the layers of composite material (106) and the layers of molybdenum sheet (122); and wherein two or more of the layers of composite material (106) each have a cutout portion (144) of surface-treated molybdenum sheet (123), and the cutout portions (144) have internal edges (148) which are staggered to avoid overlapping two or more internal edges (148).
[0002]
2. Laminate according to claim 1, characterized by the fact that the composite material layer (106) comprises a fiber-reinforced polymeric material.
[0003]
3. Laminate according to claim 1, characterized by the fact that the laminate (100) is coupled to one or more electrical sensor devices (168) that activate electrical current through the layers of molybdenum sheet (122) and that monitor any changes in the flow of electrical current through the molybdenum sheet layers (122) to obtain structural health data for a composite structure.
[0004]
4. Method (300) of forming a composite molybdenum hybrid laminate (100), characterized by the fact that the method comprises: treating (302) one surface of each one among a plurality of layers of molybdenum sheet (122), where treating the surface of the molybdenum sheet layers (122) comprises one or more surface treatments selected from the group comprising surface sol-gel treatment, water-based sol gel paint, abrasive blasting, sanding, sandblasting sand, solvent scrubbing, abrasion, laser ablation, chemical cleaning and etching by chemical corrosion; and interlacing (304) the surface-treated molybdenum sheet layers (122) with a plurality of layers of composite material (106); and, bonding (306) with an adhesive layer (134) each of the layers of surface-treated molybdenum sheet (122) to adjacent layers of composite material (106) to form a hybrid composite laminate of molybdenum (100) that has limit conventional improved elasticity; and in which two or more of the layers of composite material (106) each have a cut-out portion (144) of surface-treated molybdenum sheet (123), and where the method may additionally comprise internal step edges (148 ) of the cutout portions (144) to prevent overlapping of two or more inner edges (148).
[0005]
5. Method, according to claim 4, characterized by the fact that it also comprises the use of the composite molybdenum hybrid laminate (100) in a composite structure.
[0006]
6. Method, according to claim 5, characterized by the fact that it also comprises, after using the laminate (100) in a composite structure, coupling the laminate to one or more electrical sensor devices (168) to activate the electrical current through the layers of molybdenum sheet (122), monitoring any changes in the flow of electrical current through the layers of molybdenum sheet (122) and obtaining structural health data from the composite structure.
[0007]
7. Method, according to claim 4, characterized by the fact that the interlacing and bonding also comprise one or more of compacting, consolidating and curing layers of treated surface molybdenum sheet (122) and layers of composite material (106) intertwined.

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法律状态:
2018-04-03| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|

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2020-05-26| B09A| Decision: intention to grant|

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2020-07-28| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 27/06/2012, OBSERVADAS AS CONDICOES LEGAIS. |

优先权:

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申请号 | 申请日 | 专利标题

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US13/197,750|US9090043B2|2011-08-03|2011-08-03|Molybdenum composite hybrid laminates and methods|

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US13/197,750|2011-08-03|

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PCT/US2012/044459|WO2013019343A1|2011-08-03|2012-06-27|Molybdenum composite hybrid laminates and methods|

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