Method of manufacturing composite structures with carbon and glass reinforced composites

Abstract

The present application relates to methods of manufacturing composite structures with carbon reinforced composites and glass reinforced composites. A method for manufacturing a composite structure having a carbon reinforced composite part and a glass reinforced composite part, the method comprising contacting a glass reinforced composite material with a carbon reinforced composite material to produce a composite layup, the glass reinforced composite material having a glass reinforcement material and a polymer matrix material, wherein the glass reinforcement material has a silica content of at least 60%, and co-curing the composite layup.

Description

Technical Field

[0001] This disclosure relates to glass fiber composite gasket composite structures, and more specifically, to methods for manufacturing composite structures using carbon-reinforced composite materials and glass-reinforced composite materials. Background Technology

[0002] In industries such as aerospace and automotive, carbon fiber composites are often used in combination with metals such as aluminum to optimize strength-to-weight ratio, improve fuel efficiency, and enhance overall performance. However, when carbon fiber composites are directly attached to aluminum, galvanic corrosion occurs due to the electrochemical interactions between the carbon fibers and the aluminum. Over time, this corrosion reduces the structural integrity of the component.

[0003] To prevent this, a glass fiber composite gasket is typically placed between the carbon fiber and the metal. Glass fiber is non-conductive, acts as an insulating barrier, eliminates the risk of galvanic reactions, and ensures long-term durability in applications involving aluminum.

[0004] Despite these solutions, co-curing glass fiber layers onto structural composites remains challenging. Warpage is typically caused by the difference in the coefficients of thermal expansion (CTE) between glass fiber reinforced and carbon fiber reinforced composites. This mismatch requires complex bonding methods involving extensive surface treatments and extended curing cycles to mitigate residual stress, all of which lead to inefficiencies and high production costs.

[0005] Therefore, those skilled in the art continue to conduct research and development in the field of glass fiber composite gasket composite structures. Summary of the Invention

[0006] A method for manufacturing glass fiber composite gasket composite structures is disclosed.

[0007] In one example, the disclosed method for manufacturing a composite structure having a carbon-reinforced composite component and a glass-reinforced composite component includes contacting a glass-reinforced composite material with a carbon-reinforced composite material to produce a composite laminate, the glass-reinforced composite material comprising a glass reinforcement material and a polymer matrix material, wherein the glass reinforcement material has a low coefficient of thermal expansion, and co-curing the composite laminate.

[0008] In one example, the disclosed method for manufacturing a composite structure having a carbon fiber reinforced composite component and a glass fiber reinforced composite component includes: contacting a glass fiber reinforced composite component with a carbon fiber reinforced composite component to produce a composite laminate, the glass fiber reinforced composite component comprising a glass reinforcement having a silica content of at least 60% by weight, and co-curing the composite laminate.

[0009] In another example, the disclosed method for manufacturing a composite structure having a carbon fiber reinforced composite component and a glass fiber reinforced composite component includes: contacting a glass fiber reinforced composite material with a carbon fiber reinforced composite material to produce a composite laminate, the glass fiber reinforced composite material comprising a glass reinforcing material having a silica content of at least 60% by weight and a second polymer matrix material, the carbon fiber reinforced composite material comprising a first polymer matrix material, wherein the first polymer matrix material and the second polymer matrix material are thermoplastic; and co-consolidating the composite laminate.

[0010] The composite structure was also disclosed.

[0011] In one example, the disclosed composite structure includes a carbon-reinforced composite component and a glass-reinforced composite component connected to the carbon-reinforced composite component, wherein the glass-reinforced composite component includes a glass reinforcing material and a polymer matrix material, the glass reinforcing material having a low coefficient of thermal expansion.

[0012] In another example, the disclosed composite structure includes a carbon-reinforced composite component and a glass-reinforced composite component connected to the carbon-reinforced composite component, wherein the glass-reinforced composite component includes a glass reinforcing material and a polymer matrix material, the glass reinforcing material having a silica content of at least 60% by weight. Attached Figure Description

[0013] Figure 1A This is a flowchart illustrating an example of the disclosed method for manufacturing a composite structure having carbon-reinforced composite material and glass-reinforced composite material;

[0014] Figure 1B This is a flowchart illustrating an example of a disclosed method for manufacturing a composite structure having carbon-reinforced composite material and glass-reinforced composite material;

[0015] Figure 1C This is a flowchart illustrating an example of a disclosed method for manufacturing a composite structure having carbon-reinforced composite material and glass-reinforced composite material;

[0016] Figure 1D This is a flowchart illustrating an example of a disclosed method for manufacturing a composite structure having carbon-reinforced composite material and glass-reinforced composite material;

[0017] Figure 2A This is a schematic diagram of the cross-section of the composite structure;

[0018] Figure 2B This is a cross-sectional schematic diagram of the composite layers on the tool;

[0019] Figure 3A This is a cross-sectional schematic diagram depicting a composite structure with a single cross-linked phase;

[0020] Figure 3B This is a cross-sectional schematic diagram depicting a composite structure with a single co-consolidated phase; and

[0021] Figure 4 This is a cross-sectional schematic diagram depicting a warped composite structure. Detailed Implementation

[0022] In industries such as aerospace and automotive, carbon fiber composites are often used in combination with metals such as aluminum to optimize strength-to-weight ratio, improve fuel efficiency, and enhance overall performance. However, when carbon fiber composites are directly attached to aluminum, galvanic corrosion can occur due to the electrochemical interactions between the carbon fibers and aluminum. Over time, this corrosion can reduce the structural integrity of the component. To prevent this, a glass fiber composite gasket is typically placed between the carbon fibers and the metal. Glass fibers are non-conductive, act as an insulating barrier, eliminate the risk of galvanic reactions, and ensure long-term durability in applications involving aluminum.

[0023] Despite such solutions, the co-curing or co-consolidation of glass fiber layers in structural composites remains challenging. For example... Figure 4 As shown, warpage 4000 is typically caused by the difference in the coefficient of thermal expansion (CTE) between the glass fiber composite layer and the carbon fiber composite layer. This mismatch usually requires complex bonding methods, including extensive surface treatments and extended curing cycles to mitigate residual stress, all of which result in inefficiency and high production costs.

[0024] The disclosed methods 1000, 1001, 1002, and 1003 remedy the inefficiencies and high costs typically associated with the manufacture of glass fiber composite-gasket composite structures by eliminating unnecessary steps, such as pre-curing and surface preparation. These steps, usually required in conventional methods, result in longer production times and increased costs without adding significant value. By removing these inefficient stages, the disclosed methods not only reduce manufacturing time and costs but also simplify the overall process. This leads to higher production efficiency compared to conventional methods while maintaining the structural performance and durability of the final product.

[0025] In one iteration of the disclosed method, the polymer matrix materials 2110 and 2210 of the carbon-reinforced composite component 2010 and the glass-reinforced composite component 2020 of the composite structure 2000 can be thermosetting resins. Thermosetting resins may include, but are not limited to, epoxy resins, bismaleimide, cyanate esters, and polyimide. In cases where the disclosed method involves thermosetting resins, it is desirable to utilize materials such as... Figure 1A and Figure 1CThe co-curing step is shown. In one example, the polymer matrix material 2110 of the carbon-reinforced composite component 2010 and the polymer matrix material 2210 of the glass-reinforced composite component 2020 may be compositionally identical. In another example, the polymer matrix material 2110 of the carbon-reinforced composite component 2010 and the polymer matrix material 2210 of the glass-reinforced composite component 2020 may be compositionally different.

[0026] refer to Figure 1A and Figure 2B An example of the disclosed method for manufacturing a composite structure having a carbon fiber reinforced composite component and a glass fiber reinforced composite component (generally designated as 1000) includes: contacting a glass reinforced composite material 2200 with a carbon reinforced composite material 2100 for 1200 to produce a composite laminate 2300, the glass reinforced composite material 2200 comprising a glass reinforcement material 2220 having a silica content of at least 60% by weight; and co-curing the composite laminate 2300 for 1300.

[0027] like Figure 1C As shown, the disclosed method 1002 may further include a positioning 1102 step before contacting the glass-reinforced composite material 2200 with the carbon-reinforced composite material 2100 1202 to produce a composite laminate 2300. Positioning 1102 includes, but is not limited to, placing at least one of the glass-reinforced composite material 2200 and the carbon-reinforced composite material 2100 onto a tool surface 2501 of the tool 2500. Those skilled in the art can select the shape of the tool surface 2501 according to a given project and its specifications. In one example, the shape of the tool surface 2501 may be flat. In another example, the shape of the tool surface 2501 may be complex and irregular. The dimensions of the tool 2500 may vary depending on a given project. The dimensions of the tool 2500 may depend on the dimensions of the final product after co-curing 1300, 1302. It can be as small as a nut and bolt or as large as a part of an aircraft wing or fuselage.

[0028] refer to Figure 4 When two layers of different materials are co-cured together, the difference in their coefficients of thermal expansion (CTE) causes warpage. To minimize this warpage and potentially prevent structural failure, those skilled in the art would prefer to select composite materials with CTE values ​​as close as possible. In other words, it is desirable to select a glass-reinforced composite material 2200 comprising glass reinforcement 2220, the CTE value of which is substantially similar to the CTE of the carbon reinforcement 2120 of the carbon-reinforced composite material 2100 to which it is attached.

[0029] The CTE value of carbon-reinforced material 2120 can vary depending on the given project where the two composites are co-cured. In one example, the CTE value of carbon-reinforced material 2120 can be between about 0.5 μm / m °C and 2.5 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 0.5 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 0.75 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1.25 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1.4 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1.5 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1.6 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be approximately 1.75 μm / m℃. In another example, the CTE value of carbon-reinforced material 2120 can be approximately 2 μm / m℃. In another example, the CTE value of carbon-reinforced material 2120 can be approximately 2.25 μm / m℃. In another example, the CTE value of carbon-reinforced material 2120 can be approximately 2.5 μm / m℃.

[0030] The carbon reinforcement 2120 of the carbon-reinforced composite material 2100 can take various forms, including but not limited to carbon fibers. Those skilled in the art can select the appropriate form and orientation of the carbon reinforcement 2120 according to the specific project and its specifications. In one example, the carbon reinforcement 2120 can be continuous fibers or chopped fibers. In another example, the carbon reinforcement 2120 can take various orientations, including but not limited to unidirectional, bidirectional, and multidirectional orientations. In yet another example, the weave pattern of the carbon reinforcement 2120 can be various patterns, including but not limited to plain weave, twill weave, and satin weave. The volume fraction of the carbon reinforcement 2120 in the matrix can also vary depending on the given project.

[0031] The glass reinforcement 2220 of the glass-reinforced composite material 2200 can take various forms, including but not limited to glass fibers. Those skilled in the art can select the appropriate form and orientation of the glass reinforcement 2220 according to a given project and its specifications. In one example, the glass reinforcement 2220 can be continuous fibers or chopped fibers. In another example, the glass reinforcement 2220 can take various orientations, including but not limited to unidirectional, bidirectional, and multidirectional orientations. In yet another example, the weave pattern of the glass reinforcement 2220 can be various patterns, including but not limited to plain weave, twill weave, and satin weave. The volume fraction of the glass reinforcement 2220 in the matrix can also vary depending on the given project.

[0032] The CTE of the glass reinforcement 2220 can vary depending on the given conditions of co-curing the two composite materials. As described above, the CTE of the glass reinforcement 2220 is preferably substantially close to the CTE of the carbon reinforcement 2120 in the carbon reinforcement composite 2100 to which it is attached. In one example, the CTE of the glass reinforcement 2220 can be between about 0.1 μm / m °C and 4 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 0.4 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 0.54 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 0.7 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 1 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 1.5 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 2 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 2.5 μm / m °C. In yet another example, the CTE of the glass reinforcement 2220 can be about 2.9 μm / m °C.

[0033] One of the main factors affecting the CTE value of the glass reinforcement 2220 in glass-reinforced composite 2200 can be the percentage of silica content by weight. The percentage of silica content can affect the CTE value of glass reinforcement 2220, and therefore the overall expansion of glass-reinforced composite 2200 when exposed to heat during co-curing 1300, 1302. In other words, assuming all other factors are equal between glass-reinforced composite 2200 and carbon-reinforced composite 2100, it might be desirable to select a silica content percentage for glass reinforcement 2220 that makes its CTE as close as possible to the CTE of carbon reinforcement 2120 in carbon-reinforced composite 2100.

[0034] Therefore, it is important to select the appropriate silica content of the glass reinforcement 2220 based on the given requirements for co-curing the two composite materials. In one example, the silica content of the glass reinforcement 2220, by weight, can range from about 60% to about 99.999%. In another example, the silica content of the glass reinforcement 2220 can be about 64%. In another example, the silica content of the glass reinforcement 2220 can be about 65%. In another example, the silica content of the glass reinforcement 2220 can be about 66%. In another example, the silica content of the glass reinforcement 2220 can be about 70%. In another example, the silica content of the glass reinforcement 2220 can be about 75%. In another example, the silica content of the glass reinforcement 2220 can be about 80%. In another example, the silica content of the glass reinforcement 2220 can be about 85%. In another example, the silica content of the glass reinforcement 2220 can be about 90%. In another example, the silica content of the glass reinforcement material 2220 may be approximately 95%. In yet another example, the silica content of the glass reinforcement material 2220 may be approximately 99.999%.

[0035] Those skilled in the art may choose to use commercially available products with a specific percentage of silica content that matches the requirements of a given project. In one example, those skilled in the art may use a product trademarked as S-2 Glass, owned by AYG, headquartered at 2556 Wagner Road, Aiken, South Carolina. S-2 Glass contains approximately 64% to 66% silica by weight, which is higher than the silica content of conventional E-glass (typically between 52% and 56% by weight). In another example, those skilled in the art may use a product trademarked as Astroquartz, owned by JSP Composites, headquartered in Anderson, South Carolina. Astroquartz has a silica content of approximately 99.999% by weight.

[0036] In contrast to the example using glass reinforcement 2220 with a silica content greater than 60%, when using standard E-glass with a silica content between approximately 52% and 56%, conventional methods for manufacturing composite structure 2000, comprising carbon-reinforced composite component 2010 and glass-reinforced composite component 2020, will be required. In a non-limiting example, when the CTE value of the E-glass used as glass reinforcement 2220 is 5.4 μm / m℃ and the CTE value of the carbon reinforcement 2120 is 1.5 μm / m℃, conventional methods can be used. Due to the large difference in CTE in this case, conventional methods may involve multiple curing and other costly steps, resulting in expensive and inefficient processing. In other words, in order to co-cure the composite layers together without requiring costly additional steps (e.g., pre-curing and surface preparation), it is desirable to use glass reinforcement 2220 with a CTE value closer to that of carbon reinforcement 2120 rather than closer to that of the E-glass. In another example, the disclosed method may involve a glass reinforcement material 2220 having a low CTE value and a high silica content.

[0037] Therefore, depending on the specific project, the difference in CTE between glass reinforcement 2220 and carbon reinforcement 2120 can vary. In one example, the CTE of glass reinforcement 2220 is between approximately 30% and approximately 200% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 20% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 30% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 40% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 50% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 70% of the CTE of carbon reinforcement 2120. In yet another example, the CTE of glass reinforcement 2220 is approximately 90% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 110% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 130% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 150% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 180% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 200% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 220% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 250% of the CTE of carbon reinforcement 2120.

[0038] The glass-reinforced composite component 2020 can be used as a gasket, which reinforces the co-cured carbon-reinforced composite component 2010. The reinforcement provided by the glass-reinforced composite component 2020 can include, but is not limited to, mechanical, structural, thermal, and chemical reinforcement. (Reference) Figure 2A and Figure 2B The amount of protection and reinforcement provided by the glass-reinforced composite component 2020 can vary depending on several factors, including but not limited to the thickness, composition, degree of curing, and quality of the interface 2005 between the glass-reinforced composite component 2020 and the carbon-reinforced composite component 2010.

[0039] Co-curing with 1300 and 1302 can be performed in an autoclave. Depending on the project, the degree of cure after co-curing with 1300 and 1302 can vary. In one example, co-curing with 1300 and 1302 is performed to achieve a cure rate of 70% to 99.999% for composite structure 2000. In another example, the cure rate of composite structure 2000 after co-curing with 1300 and 1302 can be approximately 70%. In another example, the cure rate of composite structure 2000 after co-curing with 1300 and 1302 can be approximately 80%. In another example, the cure rate of composite structure 2000 after co-curing with 1300 and 1302 can be approximately 85%. In another example, the cure rate of composite structure 2000 after co-curing with 1300 and 1302 can be approximately 90%. In yet another example, the cure rate of composite structure 2000 after co-curing with 1300 and 1302 can be approximately 95%. In another example, after co-curing treatments 1300 and 1302, the degree of curing of composite structure 2000 can be approximately 99%.

[0040] refer to Figure 2A and Figure 2B Depending on the specific project, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can vary. In one example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be between about 0.02 inches and about 0.1 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.02 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.04 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.06 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.08 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.1 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.15 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.2 inches. In one embodiment, the thickness of the glass-reinforced composite material 2200 can be substantially uniform. In another embodiment, the thickness of the glass-reinforced composite material 2200 can be varied on the composite structure 2000.

[0041] Still referencing Figure 2A and Figure 2BTo properly reinforce the carbon-reinforced composite component 2010, the ratio of the carbon-reinforced composite component 2010 to the glass-reinforced composite component 2020 can be an important factor. In one example, the average cross-sectional thickness T2 of the carbon-reinforced composite component 2100 is at least twice the average cross-sectional thickness T1 of the glass-reinforced composite component 2200. In one example, the average cross-sectional thickness T2 of the carbon-reinforced composite component 2100 is at least five times the average cross-sectional thickness T1 of the glass-reinforced composite component 2200. In one example, the average cross-sectional thickness T2 of the carbon-reinforced composite component 2100 is at least ten times the average cross-sectional thickness T1 of the glass-reinforced composite component 2200. In one example, the average cross-sectional thickness T2 of the carbon-reinforced composite component 2100 is at least 15 times the average cross-sectional thickness T1 of the glass-reinforced composite component 2200.

[0042] refer to Figure 3A The integrity and quality of the composite structure 2000 after co-curing 1300 and 1302 can depend on the final state of the interface 2005 between the glass-reinforced composite component 2020 and the carbon-reinforced composite component 2010. Interface 2005 can be in a state including, but not limited to, a single crosslinked phase 3100, a gradient phase, or a combination of different phases, depending on the given project and the specific region of the interface. For example, interface 2005 can form a single crosslinked phase 3100 after co-curing 1300 and 1302. In another example, interface 2005 can generate a gradient phase after co-curing 1300 and 1302.

[0043] In another iteration of the disclosed method, the polymer matrix materials 2110 and 2210 of the carbon-reinforced composite component 2010 and the glass-reinforced composite component 2020 of the composite structure 2000 can be thermoplastic. Thermoplastic plastics can include, but are not limited to, polyether-ketone-ketone (PEKK), polyether-ether-ketone (PEEK), polyphenylene sulfide (PPS), and polyetherimide (PEI). In cases where the disclosed method involves thermoplastic plastics, it is desirable to utilize materials such as... Figure 1B and Figure 1D The co-consolidation step is shown. In one example, the polymer matrix material 2110 of the carbon-reinforced composite component 2010 and the polymer matrix material 2210 of the glass-reinforced composite component 2020 may be compositionally identical. In another example, the polymer matrix material 2110 of the carbon-reinforced composite component 2010 and the polymer matrix material 2210 of the glass-reinforced composite component 2020 may be compositionally different.

[0044] refer to Figure 1BAn example of the disclosed method 1001 for manufacturing a composite structure 2000 having a carbon-reinforced composite component 2010 and a glass-reinforced composite component 2020 includes: contacting a glass-reinforced composite material 2200 with a carbon-reinforced composite material 2100 1201 to produce a composite laminate 2300, the glass-reinforced composite material 2200 comprising a glass reinforcement material 2220 and a polymer matrix material 2210, wherein the glass reinforcement material 2220 has a silica content of at least 60% by weight; and co-consolidating the composite laminate 2300 of 1301, 1303.

[0045] like Figure 1D As shown, prior to contacting the glass-reinforced composite material 2200 with the carbon-reinforced composite material 2100 1202 to form the composite laminate 2300, the disclosed method 1003 may further include a positioning 1102 step. Positioning 1102 includes, but is not limited to, placing at least one of the glass-reinforced composite material 2200 and the carbon-reinforced composite material 2100 on the tool surface 2501 of the tool 2500. Those skilled in the art can select the shape of the tool surface 2501 according to a given project and its specifications. In one example, the shape of the tool surface 2501 may be flat. In another example, the shape of the tool surface 2501 may be complex and irregular. The dimensions of the tool 2500 may vary depending on the given project. The dimensions of the tool 2500 may depend on the dimensions of the final product after co-consolidation 1301, 1303. It can be as small as a nut and bolt or as large as a part of an aircraft wing or fuselage.

[0046] refer to Figure 4 When two layers of different materials are co-bonded together, the difference in their coefficients of thermal expansion (CTE) causes warping of 4000°. To minimize this warping and potentially prevent structural failure, those skilled in the art would prefer to select composite materials with CTE values ​​as close as possible. In other words, it is desirable to select a glass-reinforced composite material 2200 comprising glass reinforcement 2220, the CTE value of which is substantially similar to the CTE of the carbon reinforcement 2120 of the carbon-reinforced composite material 2100 to which it is attached.

[0047] The CTE value of carbon-reinforced material 2120 can vary depending on the given condition of the co-consolidation of the two composite materials. In one example, the CTE value of carbon-reinforced material 2120 can be between about 0.5 μm / m °C and 2.5 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 0.5 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 0.75 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1.25 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1.4 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1.5 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be about 1.6 μm / m °C. In another example, the CTE value of carbon-reinforced material 2120 can be approximately 1.75 μm / m℃. In another example, the CTE value of carbon-reinforced material 2120 can be approximately 2 μm / m℃. In another example, the CTE value of carbon-reinforced material 2120 can be approximately 2.25 μm / m℃. In another example, the CTE value of carbon-reinforced material 2120 can be approximately 2.5 μm / m℃.

[0048] The carbon reinforcement 2120 of the carbon-reinforced composite material 2100 can take various forms, including but not limited to carbon fibers. Those skilled in the art can select the appropriate form and orientation of the carbon reinforcement 2120 according to the specific project and its specifications. In one example, the carbon reinforcement 2120 can be provided in various lengths. In one example, the carbon reinforcement 2120 can be, but is not limited to, continuous fibers, long fibers, short fibers, and chopped fibers. In another example, the carbon reinforcement 2120 can take various orientations, including but not limited to unidirectional, bidirectional, and multidirectional orientations. In yet another example, the weave pattern of the carbon reinforcement 2120 can be various patterns, including but not limited to plain weave, twill weave, and satin weave. The volume fraction of the carbon reinforcement 2120 in the matrix can also vary depending on the given project.

[0049] The glass reinforcement 2220 of the glass-reinforced composite 2200 can take various forms, including but not limited to glass fibers. Those skilled in the art can select the appropriate form and orientation of the glass reinforcement 2220 according to a given project and its specifications. Depending on the given project, the glass reinforcement 2220 can be provided in various lengths. In one example, the glass reinforcement 2220 can be, but is not limited to, continuous fibers, long fibers, short fibers, and chopped fibers. In another example, the glass reinforcement 2220 can take various orientations, including but not limited to unidirectional, bidirectional, and multidirectional orientations. In yet another example, the weave pattern of the glass reinforcement 2220 can be various patterns, including but not limited to plain weave, twill weave, and satin weave. The volume fraction of the glass reinforcement 2220 in the matrix can also vary depending on the given project.

[0050] The CTE of the glass reinforcement 2220 can vary depending on the given condition of the co-consolidation of the two composite materials. As described above, the CTE of the glass reinforcement 2220 is preferably substantially close to the CTE of the carbon reinforcement 2120 in the carbon reinforcement composite 2100 to which it is attached. In one example, the CTE of the glass reinforcement 2220 can be between about 0.1 μm / m °C and 4 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 0.4 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 0.54 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 0.7 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 1 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 1.5 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 2 μm / m °C. In another example, the CTE of the glass reinforcement 2220 can be about 2.5 μm / m °C. In yet another example, the CTE of the glass reinforcement 2220 can be about 2.9 μm / m °C.

[0051] One of the main factors affecting the CTE value of the glass reinforcement 2220 in glass-reinforced composite 2200 can be the percentage of silica content by weight. The percentage of silica content can affect the CTE value of glass reinforcement 2220, and therefore the overall expansion of glass-reinforced composite 2200 when exposed to heat during co-consolidation 1301, 1303. In other words, assuming all other factors are equal between glass-reinforced composite 2200 and carbon-reinforced composite 2100, it might be desirable to select a silica content percentage for glass reinforcement 2220 that makes its CTE as close as possible to the CTE of carbon reinforcement 2120 in carbon-reinforced composite 2100.

[0052] Therefore, it is important to select the appropriate silica content of the glass reinforcement 2220 based on the given items of co-consolidation of the two composite materials. In one example, the silica content of the glass reinforcement 2220, by weight, can range from about 60% to about 99.999%. In another example, the silica content of the glass reinforcement 2220 can be about 64%. In another example, the silica content of the glass reinforcement 2220 can be about 65%. In another example, the silica content of the glass reinforcement 2220 can be about 66%. In another example, the silica content of the glass reinforcement 2220 can be about 70%. In another example, the silica content of the glass reinforcement 2220 can be about 75%. In another example, the silica content of the glass reinforcement 2220 can be about 80%. In another example, the silica content of the glass reinforcement 2220 can be about 85%. In another example, the silica content of the glass reinforcement 2220 can be about 90%. In another example, the silica content of the glass reinforcement material 2220 may be approximately 95%. In yet another example, the silica content of the glass reinforcement material 2220 may be approximately 99.999%.

[0053] Those skilled in the art may choose to use commercially available products with a specific percentage of silica content that matches the requirements of a given project. In one example, those skilled in the art may use a product trademarked as S-2 Glass, owned by AYG, headquartered at 2556 Wagner Road, Aiken, South Carolina. S-2 Glass contains approximately 64% to 66% silica by weight, which is higher than the silica content of conventional E-glass (typically between 52% and 56% by weight). In another example, those skilled in the art may use a product trademarked as Astroquartz, owned by JSP Composites, headquartered in Anderson, South Carolina. Astroquartz has a silica content of approximately 99.999% by weight.

[0054] In contrast to the example using glass reinforcement 2220 with a silica content greater than 60%, when using standard E-glass with a silica content between approximately 52% and 56%, conventional methods for manufacturing composite structure 2000, comprising carbon-reinforced composite component 2010 and glass-reinforced composite component 2020, will be required. In a non-limiting example, when the CTE value of the E-glass used as glass reinforcement 2220 is 5.4 μm / m °C and the CTE value of the carbon reinforcement 2120 is 1.5 μm / m °C, conventional methods can be used. Due to the large difference in CTE in this case, conventional methods may involve multiple consolidation and other costly steps, resulting in expensive and inefficient processing. In other words, in order to co-consolidate the composite layers together without requiring costly additional steps (e.g., pre-consolidation and surface preparation), it is desirable to use glass reinforcement 2220 with a CTE value closer to that of carbon reinforcement 2120 rather than closer to that of the E-glass. In another example, the disclosed method may involve a glass reinforcement material 2220 having a low CTE value and a high silica content.

[0055] Therefore, depending on the specific project, the difference in CTE between glass reinforcement 2220 and carbon reinforcement 2120 can vary. In one example, the CTE of glass reinforcement 2220 is between approximately 30% and approximately 200% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 20% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 30% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 40% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 50% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 70% of the CTE of carbon reinforcement 2120. In yet another example, the CTE of glass reinforcement 2220 is approximately 90% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 110% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 130% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 150% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 180% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 200% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 220% of the CTE of carbon reinforcement 2120. In another example, the CTE of glass reinforcement 2220 is approximately 250% of the CTE of carbon reinforcement 2120.

[0056] The glass-reinforced composite component 2020 can be used as a gasket, which reinforces the co-consolidated carbon-reinforced composite component 2010 therewith. The reinforcement provided by the glass-reinforced composite component 2020 can include, but is not limited to, mechanical, structural, thermal, and chemical reinforcement. The amount of protection and reinforcement provided by the glass-reinforced composite component 2020 can vary depending on several factors, including but not limited to the thickness, composition, degree of consolidation, and quality of the interface 2005 between the glass-reinforced composite component 2020 and the carbon-reinforced composite component 2010.

[0057] Co-consolidation 1301 and 1303 can be performed in an autoclave. Depending on the project, the degree of consolidation after co-consolidation 1301 and 1303 treatments can vary. In one example, co-consolidation 1301 and 1303 treatments are performed to achieve a degree of consolidation of composite structure 2000 between 70% and 99.999%. In another example, the degree of consolidation of composite structure 2000 after co-consolidation 1301 and 1303 treatments can be approximately 70%. In another example, the degree of consolidation of composite structure 2000 after co-consolidation 1301 and 1303 treatments can be approximately 80%. In another example, the degree of consolidation of composite structure 2000 after co-consolidation 1301 and 1303 treatments can be approximately 85%. In yet another example, the degree of consolidation of composite structure 2000 after co-consolidation 1301 and 1303 treatments can be approximately 90%. In another example, after co-consolidation treatments 1301 and 1303, the degree of consolidation of composite structure 2000 can be approximately 95%. In yet another example, after co-consolidation treatments 1301 and 1303, the degree of consolidation of composite structure 2000 can be approximately 99%.

[0058] refer to Figure 2A and Figure 2B Depending on the specific project, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can vary. In one example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be between about 0.02 inches and about 0.1 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.02 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.04 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.06 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.08 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.1 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.15 inches. In another example, the average cross-sectional thickness T1 of the glass-reinforced composite material 2200 can be about 0.2 inches. In one embodiment, the thickness of the glass-reinforced composite material 2200 can be substantially uniform. In another embodiment, the thickness of the glass-reinforced composite material 2200 can be varied throughout the composite structure 2000.

[0059] Still referencing Figure 2A and Figure 2BTo properly reinforce the carbon-reinforced composite component 2010, the ratio of the carbon-reinforced composite component 2010 to the glass-reinforced composite component 2020 can be an important factor. In one example, the average cross-sectional thickness T2 of the carbon-reinforced composite component 2100 is at least twice the average cross-sectional thickness T1 of the glass-reinforced composite component 2200. In one example, the average cross-sectional thickness T2 of the carbon-reinforced composite component 2100 is at least five times the average cross-sectional thickness T1 of the glass-reinforced composite component 2200. In one example, the average cross-sectional thickness T2 of the carbon-reinforced composite component 2100 is at least ten times the average cross-sectional thickness T1 of the glass-reinforced composite component 2200. In one example, the average cross-sectional thickness T2 of the carbon-reinforced composite component 2100 is at least 15 times the average cross-sectional thickness T1 of the glass-reinforced composite component 2200.

[0060] refer to Figure 3B The integrity and quality of the composite structure 2000 following co-consolidation 1301 and 1303 can depend on the final state of the interface 2005 between the glass-reinforced composite component 2020 and the carbon-reinforced composite component 2010. Interface 2005 can be in a state including, but not limited to, a single co-consolidation stage 3200, a gradient stage, or a combination of different stages, depending on the specific project and region of the interface. For example, interface 2005 can form a single co-consolidation stage 3200 after co-consolidation 1301 and 1303. In another example, interface 2005 can generate a gradient phase after co-consolidation 1301 and 1303.

[0061] Different examples of the disclosed methods for manufacturing composite structures having carbon-reinforced composite materials and glass-reinforced composite materials include various components, features, and functions. It should be understood that the various examples of the disclosed methods for manufacturing composite structures having carbon-reinforced composite materials and glass-reinforced composite materials may include any components, features, and functions of any other example of the methods for manufacturing composite structures having carbon-reinforced composite materials and glass-reinforced composite materials, and all such possibilities are intended to be within the scope of this disclosure.

[0062] The disclosed method for manufacturing a composite structure having carbon-reinforced composite materials and glass-reinforced composite materials is described in the context of aerospace vehicles. However, those skilled in the art will readily recognize that the disclosed method for manufacturing a composite structure having carbon-reinforced composite materials and glass-reinforced composite materials is applicable to a wide range of applications, and this disclosure is not limited to aerospace applications. For example, the disclosed method for manufacturing a composite structure having carbon-reinforced composite materials and glass-reinforced composite materials can be implemented in various types of vehicles, including, for example, helicopters, passenger ships, automobiles, marine products (boats, motors, etc.). Non-vehicle applications are also contemplated.

[0063] Although the disclosed method is used to manufacture composite structures with carbon-reinforced composites and glass-reinforced composites in an aerospace environment, it is anticipated that the disclosed method for manufacturing composite structures with carbon-reinforced composites and glass-reinforced composites can be implemented in any industry according to applicable industry standards. Specific methods for manufacturing composite structures with carbon-reinforced composites and glass-reinforced composites can be selected and customized according to specific applications.

[0064] This application involves the following terms:

[0065] 1. A method for manufacturing a composite structure, the composite structure comprising a carbon-reinforced composite component and a glass-reinforced composite component, the method comprising:

[0066] A glass-reinforced composite material is contacted with a carbon-reinforced composite material to create a composite laminate, wherein the glass-reinforced composite material comprises a glass reinforcement material and a polymer matrix material, wherein the glass reinforcement material has a low coefficient of thermal expansion; and

[0067] The composite stack is co-cured.

[0068] 2. The method according to Clause 1, wherein the composite stack comprises at least one of S-2 glass and Astroquartz.

[0069] 3. The method according to Clause 1, wherein the glass reinforcing material comprises glass fiber.

[0070] 4. The method according to Clause 1, wherein the glass reinforcing material has a high silica content.

[0071] 5. The method according to Clause 1, wherein the glass reinforcing material has a silica content of at least 60% by weight.

[0072] 6. The method according to Clause 1, wherein the glass reinforcing material has a silica content of at least 80% by weight.

[0073] 7. The method according to Clause 1, wherein the glass reinforcing material has a silica content of at least 99% by weight.

[0074] 8. The method according to Clause 1, wherein the glass reinforcement material has a coefficient of thermal expansion of 0.1 μm / m℃ to 4 μm / m℃.

[0075] 9. The method according to Clause 1, wherein the glass reinforcement material has a coefficient of thermal expansion of at least 0.5 μm / m℃.

[0076] 10. The method according to Clause 1, wherein the glass reinforcement material has a coefficient of thermal expansion of up to 4 μm / m℃.

[0077] 11. The method according to Clause 1, wherein the polymer matrix material of the glass-reinforced composite material comprises a thermosetting resin.

[0078] 12. The method according to Clause 11, wherein the thermosetting resin comprises an epoxy resin.

[0079] 13. The method according to Clause 11, wherein the thermosetting resin comprises at least one selected from epoxy resin, bismaleimide, cyanate ester and polyimide.

[0080] 14. The method according to Clause 1, wherein the carbon-reinforced composite material comprises a carbon-reinforced material and a polymer matrix material.

[0081] 15. The method according to Clause 14, wherein the carbon-reinforced material comprises carbon fiber.

[0082] 16. The method according to Clause 14, wherein the carbon-reinforced material has a coefficient of thermal expansion of up to 2 μm / m℃.

[0083] 17. The method according to Clause 14, wherein the carbon-reinforced material has a coefficient of thermal expansion of up to 1.5 μm / m °C.

[0084] 18. The method according to Clause 14, wherein the carbon-reinforced material has a coefficient of thermal expansion of at most 1 μm / m℃.

[0085] 19. The method according to Clause 14, wherein the polymer matrix material of the carbon-reinforced composite material comprises a thermosetting resin.

[0086] 20. The method according to Clause 19, wherein the thermosetting resin comprises an epoxy resin.

[0087] 21. The method according to Clause 19, wherein the thermosetting resin comprises at least one selected from epoxy resin, bismaleimide, cyanate ester and polyimide.

[0088] 22. The method according to Clause 14, wherein the polymer matrix material of the carbon-reinforced composite material and the polymer matrix material of the glass-reinforced composite material are identical in composition.

[0089] 23. The method according to Clause 14, wherein the polymer matrix material of the carbon-reinforced composite material and the polymer matrix material of the glass-reinforced composite material are different in composition.

[0090] 24. The method according to Clause 14, wherein the coefficient of thermal expansion of the glass reinforcement material is 30% to 200% of the coefficient of thermal expansion of the carbon reinforcement material.

[0091] 25. The method according to Clause 14, wherein the coefficient of thermal expansion of the glass reinforcement material is 35% to 150% of the coefficient of thermal expansion of the carbon reinforcement material.

[0092] 26. The method according to Clause 1, wherein the average cross-sectional thickness of the glass-reinforced composite material is between 0.02 inches and 0.1 inches.

[0093] 27. The method according to Clause 1, wherein the average cross-sectional thickness of the carbon-reinforced composite material is at least 10 times greater than the average cross-sectional thickness of the glass-reinforced composite material.

[0094] 28. The method according to Clause 1, wherein the co-curing is performed in an autoclave.

[0095] 29. The method according to Clause 1, wherein the co-curing is performed to achieve a curing degree of at least 90%.

[0096] 30. The method according to Clause 1, further comprising: positioning the carbon-reinforced composite material on a tool surface before bringing the glass-reinforced composite material into contact with the carbon-reinforced composite material.

[0097] 31. The method according to Clause 1, wherein the composite structure further includes an interface between the carbon-reinforced composite component and the glass-reinforced composite component, wherein the interface comprises a single crosslinked phase.

[0098] 32. A method for manufacturing a composite structure, the composite structure comprising a carbon-reinforced composite component and a glass-reinforced composite component, the method comprising:

[0099] A glass-reinforced composite material is contacted with a carbon-reinforced composite material to create a composite laminate, wherein the glass-reinforced composite material comprises a glass reinforcement material and a polymer matrix material, wherein the glass reinforcement material has a silica content of at least 60% by weight; and

[0100] The composite stack is co-consolidated.

[0101] 33. The method according to Clause 32, wherein the glass reinforcing material comprises glass fiber.

[0102] 34. The method according to Clause 32, wherein the glass reinforcing material has a silica content of at least 64%.

[0103] 35. The method according to Clause 32, wherein the glass reinforcing material has a silica content of at least 80%.

[0104] 36. The method according to Clause 32, wherein the glass reinforcing material has a silica content of at least 99%.

[0105] 37. The method according to Clause 32, wherein the glass reinforcement material has a coefficient of thermal expansion from 0.1 μm / m℃ to 4 μm / m℃.

[0106] 38. The method according to Clause 32, wherein the glass reinforcement material has a coefficient of thermal expansion of at least 0.5 μm / m℃.

[0107] 39. The method according to Clause 32, wherein the glass reinforcement material has a coefficient of thermal expansion of up to 4 μm / m℃.

[0108] 40. The method according to Clause 32, wherein the polymer matrix material of the glass-reinforced composite material comprises a thermoplastic.

[0109] 41. The method according to clause 40, wherein the thermoplastic comprises at least one of polyether-ketone-ketone (PEKK), polyether-ether-ketone (PEEK), polyphenylene sulfide (PPS), and polyetherimide (PEI).

[0110] 42. The method according to Clause 32, wherein the carbon-reinforced composite material comprises a carbon-reinforced material and a polymer matrix material.

[0111] 43. The method according to Clause 42, wherein the carbon-reinforced material has a coefficient of thermal expansion of up to 2 μm / m℃.

[0112] 44. The method according to Clause 42, wherein the carbon-reinforced material has a coefficient of thermal expansion of up to 1.5 μm / m℃.

[0113] 45. The method according to Clause 42, wherein the carbon-reinforced material has a coefficient of thermal expansion of at most 1 μm / m℃.

[0114] 46. ​​The method according to Clause 42, wherein the polymer matrix material of the carbon-reinforced composite material comprises thermoplastics.

[0115] 47. The method according to Clause 46, wherein the thermoplastic comprises at least one of polyether-ketone-ketone (PEKK), polyether-ether-ketone (PEEK), polyphenylene sulfide (PPS), and polyetherimide (PEI).

[0116] 48. The method according to Clause 42, wherein the polymer matrix material of the carbon-reinforced composite material and the polymer matrix material of the glass-reinforced composite material are identical in composition.

[0117] 49. The method according to Clause 42, wherein the polymer matrix material of the carbon-reinforced composite material and the polymer matrix material of the glass-reinforced composite material are different in composition.

[0118] 50. The method according to Clause 42, wherein the coefficient of thermal expansion of the glass reinforcement is 30% to 200% of the coefficient of thermal expansion of the carbon reinforcement.

[0119] 51. The method according to Clause 42, wherein the coefficient of thermal expansion of the glass reinforcement material is 35% to 150% of the coefficient of thermal expansion of the carbon reinforcement material.

[0120] 52. The method according to Clause 32, wherein the average cross-sectional thickness of the glass-reinforced composite material is between 0.02 inches and 0.1 inches.

[0121] 53. The method according to Clause 32, wherein the average cross-sectional thickness of the carbon-reinforced composite material is at least 10 times greater than the average cross-sectional thickness of the glass-reinforced composite material.

[0122] 54. The method according to Clause 32, wherein the co-consolidation is performed in an autoclave.

[0123] 55. The method according to Clause 32, wherein the composite structure further includes an interface between the carbon-reinforced composite component and the glass-reinforced composite component, wherein the interface comprises a single co-bonded phase.

[0124] 56. A method for manufacturing a composite structure, the composite structure comprising a carbon-reinforced composite component and a glass-reinforced composite component, the method comprising:

[0125] A glass-reinforced composite material is contacted with a carbon-reinforced composite material to create a composite laminate, wherein the glass-reinforced composite material comprises a glass reinforcement material and a polymer matrix material, and the carbon-reinforced composite material comprises a carbon reinforcement material and a polymer matrix material; and

[0126] The composite stack is co-cured.

[0127] The glass reinforcement material has a low CTE that is substantially matched with the coefficient of thermal expansion (CTE) of the carbon reinforcement material, such that the low CTE of the glass reinforcement material minimizes the residual stress that causes warping during the co-curing process.

[0128] 57. A composite structure, the composite structure comprising:

[0129] Carbon-reinforced composite components; and

[0130] A glass-reinforced composite component connected to a carbon-reinforced composite component, wherein the glass-reinforced composite component comprises a glass reinforcing material and a polymer matrix material, the glass reinforcing material having a low coefficient of thermal expansion.

[0131] 58. The composite structure according to Clause 57, wherein the glass reinforcing material has a high silica content.

[0132] 59. The composite structure according to Clause 57, wherein the glass reinforcing material has a silica content of at least 60% by weight.

[0133] 60. The composite structure according to Clause 57, wherein the glass reinforcing material has a silica content of at least 80% by weight.

[0134] 61. The composite structure according to Clause 57, wherein the glass reinforcing material has a silica content of at least 99% by weight.

[0135] 62. The composite structure according to Clause 57, the composite structure further comprising an interface between the carbon-reinforced composite component and the glass-reinforced composite component, wherein the interface comprises a single cross-linked phase.

[0136] 63. The composite structure according to Clause 57, the composite structure further comprising an interface between the carbon-reinforced composite component and the glass-reinforced composite component, wherein the interface comprises a single co-bonded phase.

[0137] Although various examples of the disclosed methods for manufacturing composite structures having carbon-reinforced composite materials and glass-reinforced composite materials have been shown and described, modifications will occur to those skilled in the art upon reading the specification. This application includes such modifications and is limited only by the scope of the claims.

Claims

1. A method for manufacturing a composite structure, the composite structure comprising a carbon-reinforced composite component and a glass-reinforced composite component, the method comprising: A glass-reinforced composite material is contacted with a carbon-reinforced composite material to create a composite laminate, wherein the glass-reinforced composite material comprises a glass reinforcement material and a polymer matrix material, wherein the glass reinforcement material has a low coefficient of thermal expansion; and The composite stack is co-cured.

2. The method according to claim 1, wherein, The composite stack includes at least one of S-2 glass and Astroquartz.

3. The method according to claim 1, wherein, The glass reinforcement material includes glass fiber.

4. The method according to claim 1, wherein, The glass reinforcement material has a high silica content.

5. The method according to claim 1, wherein, The glass reinforcement material has a silica content of at least 60% by weight.

6. The method according to claim 1, wherein, The glass reinforcement material has a silica content of at least 80% by weight.

7. The method according to claim 1, wherein, The glass reinforcement material has a silica content of at least 99% by weight.

8. A method for manufacturing a composite structure, the composite structure comprising a carbon-reinforced composite component and a glass-reinforced composite component, the method comprising: A glass-reinforced composite material is contacted with a carbon-reinforced composite material to create a composite laminate, wherein the glass-reinforced composite material comprises a glass reinforcement material and a polymer matrix material, wherein the glass reinforcement material has a silica content of at least 60% by weight; and The composite stack is co-consolidated.

9. A method for manufacturing a composite structure, the composite structure comprising a carbon-reinforced composite component and a glass-reinforced composite component, the method comprising: A glass-reinforced composite material is brought into contact with a carbon-reinforced composite material to create a composite laminate, wherein the glass-reinforced composite material comprises a glass reinforcement material and a polymer matrix material, and the carbon-reinforced composite material comprises a carbon reinforcement material and a polymer matrix material; as well as The composite stack is co-cured. The glass reinforcement material has a low CTE that is substantially matched with the coefficient of thermal expansion (CTE) of the carbon reinforcement material, such that the low CTE of the glass reinforcement material minimizes the residual stress that causes warping during the co-curing process.

10. A composite structure, the composite structure comprising: Carbon-reinforced composite components; as well as A glass-reinforced composite component connected to a carbon-reinforced composite component, wherein the glass-reinforced composite component comprises a glass reinforcing material and a polymer matrix material, the glass reinforcing material having a low coefficient of thermal expansion.

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