Co-cured UV / visible light-resistant composite material for structural aircraft assembly

Abstract

To provide a co-curable composite material assembly, a structure and a vehicle which improve the performance and reduce the weight of a structural composite material by obviating the need to include separate UV / visible light-resistant coatings formerly applied to composite material substrates.SOLUTION: Co-curable and co-cured UV / visible light-resistant composite materials are provided which have UV / visible light protection exclusively imparted to a co-curable composite material substrate assembly by a co-curable UV / visible light-resistant fiberglass layer disposed to cover the co-curable and co-cured composite material substrate.SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present disclosure relates generally to the field of composite materials, and to the field of composite materials used for large structural components. In particular, the present disclosure relates to the field of composite materials used for structural materials for the interior and exterior surfaces of large structural aircraft components. [Background technology]

[0002] The use of composite materials in the manufacture of various structural component parts continues to grow. At least due to their strength-to-weight ratio, composite materials offer advantages as alternatives to higher density materials such as metals and metal alloys. The overall weight of a finished structure (or the weight of a component part of a finished structure) is an important consideration in the selection of materials used in the manufacture of such a finished structure or in the manufacture of a component of a finished structure.

[0003] Coating layers applied to composite materials are not as durable or long-lived as the composite materials to which they are applied. Composite material assemblies may also include other exterior or interior layers, which may include, for example, protective or other coating layers. For example, when composite materials are used in the manufacture of vehicles, including aircraft, the exterior paint coatings on the aircraft, often referred to as "livery," may require modification, touch-ups, changes to logos, designs, color schemes, and the like, over the life of the vehicle. Such livery modification may include, for example, the removal of one or more decorative coating layers applied over the composite material, including one or more paint layers. However, removing one layer or layer type (e.g., paint, primer, adhesion-promoting layer, adhesive layer) from a material layered over the composite material may require the removal of additional layers or layer types, which may then require building up or other restructuring. Additionally, color modification requiring paint removal via paint removal techniques may damage underlying layers or even the composite material if the composite material is subjected to excessive mechanical paint removal techniques.

[0004] Unless expressly stated otherwise, nothing in this specification is admitted to be prior art merely by virtue of its inclusion in the Technical Field and / or Background Art. Summary of the Invention

[0005] Disclosed herein are co-curable and co-cured composites that include a co-curable or co-cured layer of UV / visible light resistant fiberglass in direct contact with a co-curable composite structural material substrate. The incorporation of a co-curable / co-cured UV / visible light resistant fiberglass layer into a composite structural material substrate can significantly impact composite manufacturing, improving performance and reducing the weight of structural composites by at least eliminating the need to include a separate UV / visible light resistant coating that was previously applied to the composite substrate, such as in preparing composite systems for use in structural assemblies for larger components, including exterior and interior surfaces of vehicles, including aircraft.

[0006] According to this aspect, a co-curable composite assembly is disclosed that includes a co-curable composite substrate and a co-curable UV / visible light-resistant fiberglass-containing layer. The co-curable composite substrate includes a first side of the co-curable composite substrate and a second side of the co-curable composite substrate. The co-curable UV / visible light-resistant fiberglass-containing layer includes a first side of the co-curable UV / visible light-resistant fiberglass-containing layer and a second side of the co-curable UV / visible light-resistant fiberglass-containing layer. The co-curable UV / visible light-resistant fiberglass-containing layer has a UV / visible light transmittance value in the range of about 0% to about 20% for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the co-curable UV / visible light-resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils.

[0007] In another embodiment, the co-curable composite substrate is co-curable with the co-curable UV / visible light resistant fiberglass-containing layer at a temperature ranging from about 250 degrees Fahrenheit to about 370 degrees Fahrenheit.

[0008] In another aspect, the co-curable composite substrate comprises a carbon fiber reinforced polymer.

[0009] In another aspect, a co-curable composite substrate comprises an epoxy resin-based compound, and the co-curable composite substrate further comprises at least one of carbon fiber, boron fiber, aramid fiber, fiberglass fiber, polyester fiber, and combinations thereof.

[0010] In yet another aspect, a co-curable composite substrate includes a plurality of carbon fiber reinforced polymer prepregs.

[0011] In another embodiment, the second side of the co-curable composite substrate is in direct contact with the first side of the co-curable UV / visible light resistant fiberglass-containing layer, and the co-curable UV / visible light resistant fiberglass-containing layer completely covers the second side of the co-curable composite substrate.

[0012] According to another present aspect, a co-cured composite assembly is disclosed that includes a co-cured composite substrate and a co-cured UV / visible light resistant fiberglass-containing layer. The co-cured composite substrate includes a first side of the co-cured composite substrate and a second side of the co-cured composite substrate. The co-cured UV / visible light resistant fiberglass-containing layer includes a first side of the co-cured UV / visible light resistant fiberglass-containing layer and a second side of the co-cured UV / visible light resistant fiberglass-containing layer. The co-cured composite substrate and the co-cured UV / visible light resistant fiberglass-containing layer are configured to be co-cured using a co-cure regimen. The co-cure regimen includes a curing temperature ranging from about 250°F to about 370°F. The co-cured UV / visible light resistant fiberglass-containing layer has a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the co-cured UV / visible light resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils.

[0013] In another aspect, a co-cured composite substrate includes a fiber reinforced epoxy resin matrix, the fiber reinforced epoxy resin matrix including at least one of carbon fiber, boron fiber, aramid fiber, fiberglass fiber, polyester fiber, and combinations thereof.

[0014] In another aspect, a co-cured composite substrate includes a plurality of carbon fiber reinforced polymer composite prepregs.

[0015] In another aspect, the inclusion of a curable, then substantially cured, UV / visible light resistant fiberglass-containing layer in the curable, then substantially cured composite assembly eliminates the need for a detail primer layer and / or a UV absorbing paint layer in the final co-cured composite assembly.

[0016] In yet another aspect, a structure is disclosed. The structure includes a co-cured composite assembly including a co-cured composite substrate and a co-cured UV / visible light resistant fiberglass-containing layer. The co-cured composite substrate includes a first side of the co-cured composite substrate and a second side of the co-cured composite substrate. The co-cured UV / visible light resistant fiberglass-containing layer includes a first side of the co-cured UV / visible light resistant fiberglass-containing layer and a second side of the co-cured UV / visible light resistant fiberglass-containing layer. The co-cured composite substrate and the co-cured UV / visible light resistant fiberglass-containing layer are configured to be co-cured using a co-cure regimen. The co-cure regimen includes a cure temperature ranging from about 250°F to about 370°F. The co-cured UV / visible light resistant fiberglass-containing layer has a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the co-cured UV / visible light resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils.

[0017] In another aspect, the structure includes at least one of an aircraft wing assembly, an aircraft horizontal stabilizer assembly, a vertical stabilizer assembly, and combinations thereof.

[0018] In another aspect, the structure includes a wing assembly for an aircraft.

[0019] In a further aspect, the inclusion of a co-cured UV / visible light resistant fiberglass-containing layer in the co-cured composite assembly obviates the need for the presence of at least one of a detail primer layer and a UV absorbing paint layer in the final co-cured composite assembly.

[0020] In another aspect, the structure includes an outer mold line of an aircraft wing assembly, and the second side of the UV / visible light resistant fiberglass-containing layer is configured to support at least one of a primer and a topcoat of the assembly.

[0021] In another aspect, the structure is a vehicle.

[0022] In a further aspect, the vehicle is selected from the group consisting of a manned aerial vehicle, an unmanned aerial vehicle, a manned spacecraft, an unmanned spacecraft, a manned rotorcraft, an unmanned rotorcraft, a manned ground vehicle, an unmanned ground vehicle, a manned surface vehicle, an unmanned surface vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

[0023] In another present aspect, a method is disclosed. The method includes providing a co-curable composite substrate. The co-curable composite substrate includes a co-curable composite substrate first side and a co-curable composite substrate second side. The method further includes applying a co-curable UV / visible light-resistant fiberglass-containing layer onto the second side of the co-curable composite substrate. The co-curable UV / visible light-resistant fiberglass-containing layer has a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the co-curable UV / visible light-resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils. The method further includes co-curing the co-curable composite substrate with the co-curable UV / visible light-resistant fiberglass-containing layer to form a co-cured composite assembly for aircraft structure.

[0024] In another aspect, a co-cured composite assembly includes an outer mold line.

[0025] In a further aspect, the co-cured composite assembly formed according to the disclosed method does not include a UV / visible light resistant paint or UV / visible light resistant primer layer positioned within the co-cured composite assembly.

[0026] In another aspect, the method includes co-curing a co-curable composite substrate with a co-curable UV / visible light resistant fiberglass-containing layer at a co-cure temperature ranging from about 250° F. to about 370° F. to form a co-cured composite assembly for an aircraft structure. The aircraft structure includes at least one of an aircraft wing assembly, a horizontal stabilizer assembly, a vertical stabilizer assembly, and combinations thereof.

[0027] In another embodiment, a co-curable UV / visible light resistant fiberglass-containing layer is applied to a co-curable carbon fiber as a single ply.

[0028] In another aspect, the co-curable composite substrate comprises a carbon fiber reinforced polymer composite substrate.

[0029] In another aspect, the co-cured composite substrate comprises a carbon fiber reinforced polymer composite substrate.

[0030] In another aspect, a co-curable composite substrate includes a fiber reinforced epoxy resin matrix, the fiber reinforced epoxy resin matrix including at least one of carbon fiber, boron fiber, aramid fiber, fiberglass fiber, polyester fiber, and combinations thereof.

[0031] In another aspect, a co-cured composite substrate includes a fiber reinforced epoxy resin matrix, the fiber reinforced epoxy resin matrix including at least one of carbon fiber, boron fiber, aramid fiber, fiberglass fiber, polyester fiber, and combinations thereof.

[0032] In further aspects, co-cured composite assemblies made according to the disclosed methods are disclosed.

[0033] The above-described features, functions, and advantages can be realized alone in various aspects or combined in yet other aspects, details of which can be ascertained by reference to the following description and accompanying drawings.

[0034] Having therefore described aspects of the present disclosure in general terms, reference is now made to the accompanying drawings, which are not necessarily drawn to scale, and in which: [Brief explanation of the drawings]

[0035] [Figure 1] 1 is a diagram of a vehicle in the form of an aircraft according to present aspects; [Figure 2A] FIG. 2 is an enlarged cross-sectional representative side view of a co-curable UV / visible light resistant composite material according to the present embodiment. [Figure 2B]FIG. 2 is an enlarged cross-sectional representative side view of a co-cured UV / visible light resistant composite material according to the present embodiment. [Figure 2C] FIG. 1 is an enlarged cross-sectional representative side view of a co-cured UV / visible light resistant composite material system according to the present embodiment, with a reduced detail primer layer and no separate UV / visible light resistant paint layer. [Figure 2D] FIG. 1 is an enlarged cross-sectional representative side view of a co-cured UV / visible light resistant composite material system according to the present embodiment, without the presence of either a detail primer layer or a separate UV / visible light resistant paint layer. [Figure 3] 1 is a flowchart outlining a method according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0036] For example, layers of material, which may be applied as coatings, may be added to a composite surface to alter the surface properties of the composite. For example, a primer or other coating layer may be added to a composite to improve the adhesion of a subsequent coating layer, such as a paint or topcoat, to the composite surface, which may already have one or more other coatings applied. The layering of coating materials onto a composite surface is laborious and time-consuming and can add substantial weight to large objects or structures that include such composites with multiple coating layers.

[0037] Additionally, paint removal processes that remove various paint coating layers from composite materials often damage protective surface layers added to the composite material, and when a paint removal process is applied underneath a paint coating layer, the paint coating layer may peel from the surface layer, requiring significant resurfacing work. For example, one or more of the composite coating layers may each require separate surface preparation steps and procedures before one or more coating layers are subsequently deposited on the composite surface. In some cases, portions of one or more previously deposited coatings need to be removed or otherwise reworked before the addition of additional coating layers. Such intermediate rework of the composite surface during processing of the composite surface is also labor-intensive, time-consuming, and expensive.

[0038] During the manufacture of composite parts, which may include, for example, epoxy resin-based composites or carbon fiber reinforced polymer materials, the composite surface may begin to deteriorate due to exposure to ambient ultraviolet / visible (UV / visible) radiation. To avoid changes in the surface properties of the composite, which may be caused, at least in part, by exposure of the composite to UV / visible radiation, the composite surface is often protected by a polymer cover or coated with at least one protective layer, such as, for example, a spray-on surfacer or primer layer. The protective layer may, for example, contain a UV "blocking" agent.

[0039] Adding UV mitigation or "blocking" agents as layers to composite surfaces often adds manufacturing complexity, at a minimum, increasing manufacturing time, increasing rework time, increasing overall production costs, etc., because such added UV-blocking material coverings are typically removed from the composite or chemically or mechanically reactivated before further processing of the composite assembly occurs. In addition, primer or surfacing film layers are often treated to accept subsequent paint layers or topcoats. This treatment of each subsequent layer added to the composite system (which may be layers disposed in a "stack" on the composite substrate) again increases manufacturing time, increases rework time, increases overall production costs, etc.

[0040] Composite materials are typically post-treated or "reworked," e.g., to repaint and / or resurface the composite material. For example, a primer or paint coating containing a UV mitigating or UV "blocking" agent may be applied to the composite surface to protect it from deterioration and / or discoloration that may be caused, for example, by exposing the composite to ultraviolet / visible light (UV / visible) radiation during use of the composite material as a building material in the manufacture of a larger structure.

[0041] Additionally, during aircraft manufacturing and aircraft use, UV / visible light damage from UV / visible light wavelengths that affect coating layers used to coat composite materials and / or that affect the underlying composite material can result in composite materials requiring material rework. Exposure to UV / visible light radiation can change material properties over time. For example, UV / visible light radiation can make a coating layer or composite material vulnerable to processing damage, such as when the coating layer or composite material is subjected to mechanical paint removal techniques. Selecting material layers for large structures to protect against environmental damage, including UV / visible light damage, can result in the need for a series of coating layers. The addition of each such coating layer can result in significant amounts of time and expense and add weight to large structures, including aircraft (weight considerations can further affect fuel used, cargo and passenger capacity, aircraft range, etc.).

[0042] Disclosed herein are present embodiments directed to co-curable and co-cured composites that include a co-curable or co-cured layer of UV-resistant fiberglass in direct contact with a composite substrate. The incorporation of a co-cured and co-curable UV / visible light resistant fiberglass layer into a composite substrate can significantly impact composite manufacturing, improving performance and reducing the weight of structural composites by at least eliminating the need to include a separate UV-resistant coating previously applied to the composite substrate to protect the composite from UV / visible light damage and in preparing composite systems for use in structural assemblies for larger components, including interior and exterior surfaces of vehicles, including aircraft.

[0043] According to the present aspect, a method for improving UV / visible light protection and reducing UV / visible light degradation of a composite material is disclosed. Also disclosed is a composite substrate with improved UV / visible light protection without the previously required presence of a typically added protective cover or primer layer or other layer (e.g., UV-absorbing paint). In addition to preventing UV / visible light degradation of the underlying composite substrate surface, the disclosed methods, systems, and apparatus eliminate the need for protective covers, protective primer layers, and UV-absorbing paint layers, resulting in a reduction in the complexity and overall weight of the composite material system, which further reduces composite processing time. Reducing UV / visible light degradation of the composite material also reduces the occurrence of the need for rework of the composite material (necessitated by such UV / visible light degradation).

[0044] Figure 1 is a diagram of a vehicle in the form of an aircraft according to the present embodiment. As shown in Figure 1, aircraft 10 includes a main wing assembly 12, a horizontal stabilizer assembly 14, and a vertical stabilizer assembly 16. Composite materials of the present disclosure can be configured to form or be otherwise configured to form a variety of aircraft assemblies, including the one shown in Figure 1.

[0045] According to this aspect, there is provided a composite substrate that may comprise an epoxy resin-based composite material combined with a fiber matrix that may comprise carbon fiber, boron fiber, aramid fiber, fiberglass fiber, polyester fiber, and combinations thereof, with carbon fiber being particularly preferred as the composite substrate, and carbon fiber reinforced polymer being especially preferred.

[0046] According to a further aspect of the present disclosure, the composite material used in the manufacture of the composite structure further comprises a UV / visible light resistant layer (equivalently referred to herein as a UV / visible light suppressive layer). The UV / visible light resistant layer takes the form of a fiberglass layer, which may be a single fiberglass ply. According to a further aspect of the present disclosure, the UV / visible light resistant fiberglass layer is provided in intimate contact with the material of a composite substrate. The composite substrate is co-curable with the co-curable UV / visible light resistant fiberglass layer.

[0047] The composite substrate, also referred to herein as a base layer or underlayer or composite substrate layer, can be an epoxy resin-based material, including a fiber-reinforced polymer composite, which can have an epoxy resin-based matrix, and can be a co-curable composite, which can include a carbon fiber-reinforced composite. In this embodiment, the co-curable composite can be any suitable composite that can be co-cured with a co-curable fiberglass-containing material at a temperature ranging from about 250° F. to about 370° F.

[0048] Composite materials are often built up into laminates with a selected number of composite layers (called "prepregs"). Prepregs can be "pre-impregnated" composite fibers with a matrix material already present, such as an epoxy resin-based material. The fibers are often in the form of a fabric, and the matrix is ​​used to bond them together and to other components during manufacturing. Composite matrix materials are typically partially cured to allow for easy handling. Such composite matrix materials may require cooling or refrigeration to prevent further partial or complete curing; such composite matrix materials are called B-stage materials. Consequently, B-stage prepregs are stored in a cooled area because ambient heat can promote complete polymerization. Prepregs can also be impregnated with a bulk amount of fibers and then stored in a cooled area for extended periods of time until later curing. Prepregs are typically formed on a flat, workable surface. The stack of prepreg plies can then be formed thereon using a molding or forming tool, also called a mandrel, and shaped into a desired shape if desired. This embodiment uses, but is not limited to, layup layers of composite prepreg to form co-curable and co-cured composite substrates.

[0049] According to this aspect, a "co-curable" material is defined as a material that can be co-cured with another material, whereby two co-curable materials will co-cure when exposed to common curing conditions, such as those that can be imposed by a predetermined curing regimen (predetermined temperature, pressure, ramp-up temperature / rate, dwell time, etc.) to form a "co-cured" composition.

[0050] According to this embodiment, a selected degree of UV / visible light resistance and UV / visible light protection can be imparted to the composite substrate exclusively by directly contacting the co-curable composite surface with the co-curable UV / visible light resistant fiberglass layer after co-curing to form a co-cured UV / visible light resistant fiberglass coated composite. That is, according to this embodiment, previously required UV / visible light resistant primers, UV blocking paints, and the like, can be eliminated or their presence made unnecessary, since their UV protection function within the UV / visible light resistant composite is fulfilled exclusively by the addition and placement of the co-curable UV / visible light resistant fiberglass layer provided in direct contact with the co-curable composite substrate.

[0051] By co-curing the UV / visible light resistant fiberglass layer with the composite, benefits are imparted by the co-cured UV / visible light resistant fiberglass layer of the present disclosure to at least the underlying epoxy-based composite, as well as to the final co-cured composite substrate and any composite structural substrate incorporating the co-cured composite substrate. According to this aspect, such imparted benefits include, but are not limited to, UV / visible light protection of the epoxy-based composite and protection of the composite substrate from the deleterious effects of mechanical paint removal techniques.

[0052] Additionally, the robustness of the co-curable UV / visible light resistant fiberglass layer of the present disclosure, co-cured onto, for example, a co-curable epoxy-based composite substrate, can withstand subsequent and repeated heat treatments that may be required during subsequent and repeated repaint protocols. That is, unlike some currently required repaint protocols, the co-cured UV / visible light resistant fiberglass layer of the present disclosure does not need to be replaced, removed, or otherwise reapplied during rework, paint removal, repainting, repeated heat treatments, etc. That is, the present embodiment contemplates the removal or reconditioning of only the layers (e.g., topcoat layer, basecoat layer, clearcoat layer, intermediate coating layer, etc.) coated onto the co-cured UV / visible light resistant fiberglass-containing layer of the present disclosure.

[0053] Through the use of the co-cured UV / visible light resistant fiberglass coated composite substrate of the present disclosure, a significant number of previously required procedural steps that would otherwise be required during repainting or rework of the composite substrate are eliminated. As a result, substantial reductions in resources, including, for example, material costs to replace layers damaged by UV / visible light, and manpower hours previously required for additional processing of individual layers (e.g., individual pre-layer surfacing steps, layer application steps, and post-layer surfacing steps, including chemical application, physical surfacing (including sanding, etc.), inspection of deposited layers, etc.), are eliminated.

[0054] According to this embodiment, FIG. 2A shows an enlarged, cross-sectional, representative side view of a co-curable composite assembly 20a, consisting of a co-curable composite material 22a having a co-curable UV / visible light-resistant fiberglass layer 24a disposed thereon. According to this embodiment, the co-curable composite material assembly 20a can be co-cured to form a co-cured composite material. The co-curable composite material assembly 20a is subjected to a co-curing regimen in which the co-curable UV / visible light-resistant fiberglass layer 24a disposed on the co-curable composite material substrate 22a is co-cured at a curing temperature below 400°F, more preferably at a temperature in the range of about 250°F to about 370°F, for a suitable duration to co-cure the two components and form a co-cured UV / visible light-resistant composite material. As shown in FIG. 2A, the co-curable composite material substrate 22a can be a co-curable carbon fiber reinforced polymer composite substrate. It can also be a co-curable epoxy resin-based composite substrate.

[0055] Figure 2B shows a co-cured UV / visible light resistant composite 20b formed from the uncured components shown in Figure 2A, and in the cured state shown in Figure 2B, includes a co-cured composite substrate 22b and a co-cured (co-cured) UV / visible light resistant fiberglass layer 24b. According to this embodiment, the co-cured UV / visible light resistant fiberglass 24b can be a single ply or two or more plies. The co-cured UV / visible light resistant fiberglass layer 24b can exclusively impart (i.e., be essentially 100% responsible for imparting) a selected degree of UV / visible light protection to the underlying co-cured composite substrate 22b. Thereby, the co-cured UV / visible light resistant fiberglass layer has a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the co-cured UV / visible light resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils.

[0056] According to this embodiment, the UV / visible light resistant fiberglass layer is selected to have UV / visible light resistance properties and values. The co-cured UV / visible light resistant fiberglass layer is thereby solely responsible for imparting a degree of UV / visible light resistance and UV / visible light protection to the underlying epoxy resin-based composite. That is, according to this embodiment, the UV / visible light blocking capability of the co-cured UV / visible light resistant fiberglass layer eliminates the need for, renders redundant, or otherwise unnecessary the presence of any additional UV / visible light resistant layers within the composite system. These include, for example, UV / visible light resistant paints, UV / visible light resistant primers, and UV / visible light resistant topcoats. This capability also obviates the need to incorporate UV / visible light blockers into the containing material substrate. Instead, the overall UV / visible light blocking function for the co-cured composite assemblies of the present disclosure and for structures incorporating the co-cured composite assemblies of the present disclosure is entirely satisfactory. This is due to the UV / visible light blocking capability introduced into the resulting co-cured composite assembly by the UV / visible light resistant fiberglass layer, which may be, for example, a single-ply UV / visible light resistant fiberglass layer. Again, according to this aspect, no additional UV / visible light resistant layer is required to achieve the desired and selected UV / visible light blocking functionality for the co-cured composite assemblies of the present disclosure.

[0057] According to this embodiment, a co-cured UV / visible light resistant composite assembly of the type shown in Figure 2B can be used as a structural composite for the manufacture of vehicle structural components and structural component assemblies, including, for example, aircraft wing assemblies, aircraft horizontal stabilizers, and aircraft vertical stabilizers. Thus, when configured as various aircraft structural composites, a co-cured UV / visible light resistant composite assembly 20b of the type shown in Figure 2B is configured to accept or otherwise facilitate the addition of various primer and topcoat layers that will become part of, or precede the formation of, the exterior of a larger structural assembly, such as, for example, an aircraft livery on a larger structural assembly for an aircraft.

[0058] Figure 2C is an enlarged, cross-sectional, representative side view of a co-cured UV / visible light resistant composite assembly 20c in the form of a material system further including the co-cured UV / visible light resistant composite assembly layer shown in Figure 2B (as assembly 20b). That is, Figure 2C shows a co-cured composite substrate 22c in which a co-cured UV / visible light resistant fiberglass layer 24c is disposed on a co-cured epoxy resin composite substrate 22c. As further shown in Figure 2c, according to this embodiment, the co-cured UV / visible light resistant composite assembly does not include any additional UV / visible light resistant materials (e.g., in the form of one or more UV / visible light resistant primer layers or one or more UV / visible light resistant paint layers, etc.). That is, as shown in FIG. 2C, according to this embodiment, UV / visible light resistant fiberglass layer 24c is solely responsible for imparting UV / visible light resistance to UV / visible light resistant composite assembly 20c (e.g., by preventing UV / visible light radiation from penetrating through the co-cured UV / visible light resistant fiberglass layer to the underlying co-cured composite substrate).

[0059] As shown in FIG. 2C , co-cured UV / visible light-resistant composite assembly 20c further includes detail primer layer 25c, assembly primer layer 26c, and topcoat layer 28c covering co-cured UV / visible light-resistant fiberglass layer 24c. According to this embodiment, the average thickness of the detail primer layer is significantly reduced from the amount and layer thickness of detail primer previously required in known composite assemblies. In particular, the present co-cured UV / visible light-resistant composite assembly including the UV / visible light-resistant fiberglass layer may facilitate reducing the thickness or eliminating the presence of the initial primer. Such reduction or elimination of the initial primer thickness may result in significant weight reduction, cost reduction, reduced processing time, reduced rework time, reduced man-hour labor, and reduced material requirements, depending on the scale of large structures, including large structural assemblies, including, for example, aircraft.

[0060] Figure 2D is an enlarged, cross-sectional, representative side view of co-cured UV / visible light resistant composite assembly 20d in the form of a composite assembly further including the co-cured UV / visible light resistant composite assembly layer shown in Figure 2B (as assembly 20b). That is, Figure 2D shows co-cured composite substrate 22d in which co-cured UV / visible light resistant fiberglass layer 24d is disposed on co-cured composite substrate 22d. As further shown in Figure 2D, according to this embodiment, the co-cured UV / visible light resistant composite assembly does not include any additional UV / visible light resistant material in the form of UV / visible light resistant primer layer(s) or UV / visible light resistant paint layer(s). That is, as shown in FIG. 2D , according to this embodiment, UV / visible light resistant fiberglass layer 24d is solely responsible for imparting UV / visible light resistance to UV / visible light resistant composite assembly 20d (e.g., by preventing UV / visible light radiation from penetrating the fiberglass layer to the underlying composite substrate).

[0061] As shown in FIG. 2D , the co-cured UV / visible light-resistant composite assembly 20d does not include a detail primer layer, such as detail primer layer 25c shown in FIG. 2C . As shown in FIG. 2D , the co-cured UV / visible light-resistant composite assembly 20d further includes assembly primer layer 26d and topcoat layer 28d, covering co-cured UV / visible light-resistant fiberglass layer 24d. According to this embodiment, eliminating or otherwise dispensing with the detail primer layer from the co-cured UV / visible light-resistant composite assembly reduces the complexity of composite preparation, which can result in significant weight savings, cost savings, processing time savings, rework time savings, man-hour labor savings, and reduced material requirements, depending on the scale of large structures with large structural assemblies, including aircraft. As shown in FIGS. 2B , 2C , and 2D , the co-cured composite structure can be a co-cured carbon fiber reinforced polymer composite substrate. It can also be a co-cured epoxy resin-based composite substrate.

[0062] 4 is a flowchart outlining a method for making the co-curable and co-cured composite materials of the present disclosure. Further present aspects contemplate structures comprising at least one of the co-curable and co-cured composite materials, assemblies comprising the co-cured composite materials, subassemblies comprising the co-cured composite materials, and assemblies and / or subassemblies comprising the co-cured UV / visible light resistant composite materials made according to the methods described herein. The structures include, for example, manned aerial vehicles, unmanned aerial vehicles, manned spacecraft, unmanned spacecraft, manned rotorcraft, unmanned rotorcraft, manned ground vehicles, unmanned ground vehicles, manned surface vehicles, unmanned surface vehicles, manned underwater vehicles, unmanned underwater vehicles, satellites, and combinations thereof.

[0063] As shown in FIG. 4, method 100 is generally illustrated. Method 100 includes providing a co-curable composite substrate (102), which may be a co-curable carbon fiber reinforced polymer substrate and may further be a co-curable epoxy resin-based composite substrate. Method 100 further includes placing and applying a co-curable UV / visible light-resistant fiberglass layer (104) over the co-curable composite layer, which may be a co-curable epoxy resin-based composite substrate and may further be a carbon fiber reinforced polymer. According to this embodiment, the co-curable UV / visible light-resistant fiberglass layer may be a single ply or multiple plies, whereby the co-curable UV / visible light-resistant fiberglass layer has a UV / visible light transmittance value in the range of about 0% to about 20% for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the co-cured UV / visible light-resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils. The co-curable UV / visible light resistant composite assembly including the UV / visible light resistant fiberglass-containing layer can be of the type shown and described in at least one of Figures 2A and 2C and described herein. Method 100 further includes co-curing the co-curable composite layer, which can be a co-curable epoxy resin-based composite substrate, with the co-curable UV / visible light resistant fiberglass-containing layer at a temperature in the range of about 250°F to about 370°F to form a co-cured UV / visible light resistant composite assembly of the type shown and described in at least one of Figures 2B, 2C, and 2D and described herein.

[0064] Furthermore, the present disclosure includes embodiments according to the following clauses:

[0065] Article 1. A co-curable composite assembly (20a) comprising: a co-curable composite substrate (22a), comprising a co-curable composite substrate first side (22a') and a co-curable composite substrate second side (22a"); and a co-curable UV / visible light resistant fiberglass-containing layer (24a), comprising a co-curable UV / visible light resistant fiberglass-containing layer first side (24a') and a co-curable UV / visible light resistant fiberglass-containing layer second side (24a"); a co-curable composite material assembly, wherein the co-curable UV / visible light resistant fiberglass-containing layer has a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the co-curable UV / visible light resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils.

[0066] Article 2. 10. The co-curable composite assembly of clause 1, wherein the co-curable composite substrate is co-curable with the co-curable UV / visible light resistant fiberglass-containing layer at a temperature ranging from about 250 degrees Fahrenheit to about 370 degrees Fahrenheit.

[0067] Article 3. 10. The co-curable composite assembly of claim 1, wherein the co-curable composite substrate comprises a carbon fiber reinforced polymer.

[0068] Article 4. 10. The co-curable composite assembly of claim 1, wherein the co-curable composite substrate comprises an epoxy resin-based compound, and the co-curable composite substrate further comprises at least one of carbon fiber, boron fiber, aramid fiber, fiberglass fiber, polyester fiber, and combinations thereof.

[0069] Article 5. 10. The co-curable composite assembly of claim 1, wherein the co-curable composite substrate comprises a plurality of carbon fiber reinforced polymer prepregs.

[0070] Article 6. 10. The co-curable composite assembly of claim 1, wherein the second side of the co-curable composite substrate is in direct contact with the first side of the co-curable UV / visible light resistant fiberglass-containing layer, and the co-curable UV / visible light resistant fiberglass-containing layer completely covers the second side of the co-curable composite substrate.

[0071] Article 7. A co-cured composite assembly (20b) comprising: a co-cured composite substrate (22b), comprising a composite substrate first side (22b') and a composite substrate second side (22b'); and a co-cured UV / visible light resistant fiberglass-containing layer (24b), the co-cured UV / visible light resistant fiberglass-containing layer (24b) comprising a co-cured UV / visible light resistant fiberglass-containing layer first side (24b') and a co-cured UV / visible light resistant fiberglass-containing layer second side (24b"); the co-cured composite substrate and the co-cured UV / visible light resistant fiberglass-containing layer are co-cured in a co-cure regimen comprising a co-cure temperature in the range of about 250°F to about 370°F; a co-cured composite material assembly, wherein the co-cured UV / visible light resistant fiberglass-containing layer has a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the co-cured UV / visible light resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils.

[0072] Article 8. 8. The co-cured composite assembly of clause 7, wherein the co-cured composite substrate comprises a fiber reinforced epoxy resin matrix, the fiber reinforced epoxy resin matrix comprising at least one of carbon fiber, boron fiber, aramid fiber, fiberglass fiber, polyester fiber, and combinations thereof.

[0073] Article 9. 8. The co-cured composite assembly of clause 7, wherein the co-cured composite substrate comprises a plurality of carbon fiber reinforced polymer composite prepregs.

[0074] Article 10. 8. The co-cured composite assembly of clause 7, wherein the inclusion of the co-cured UV / visible light resistant fiberglass-containing layer in the co-cured composite assembly obviates the presence of at least one of a detail primer layer and a UV / visible light absorbing paint layer in the final co-cured composite assembly.

[0075] Article 11. 10. A structure comprising the co-cured composite assembly of claim 7, the structure comprising an outer mold line of an aircraft wing assembly, wherein a second side of the co-cured UV / visible light resistant fiberglass-containing layer is configured to support at least one of a primer (26c)(26d) and a topcoat (28c)(28d) of the assembly.

[0076] Article 12. 10. A structure comprising the co-cured composite material assembly of claim 7, the structure comprising at least one of an aircraft wing assembly (12), an aircraft horizontal stabilizer assembly (14), a vertical stabilizer assembly (16), and combinations thereof.

[0077] Article 13. 10. A structure (10) comprising the co-cured composite assembly of clause 7, the structure comprising a wing assembly of an aircraft.

[0078] Article 14. A vehicle (10) including a structure as described in clause 12.

[0079] Article 15. A vehicle (10) including a structure as described in clause 13.

[0080] Article 16. The vehicle is 15. The vehicle of clause 14 selected from the group consisting of a manned aerial vehicle, an unmanned aerial vehicle, a manned spacecraft, an unmanned spacecraft, a manned rotorcraft, an unmanned rotorcraft, a manned ground vehicle, an unmanned ground vehicle, a manned surface vehicle, an unmanned surface vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

[0081] Article 17. The vehicle is 16. The vehicle of clause 15, selected from the group consisting of a manned aerial vehicle, an unmanned aerial vehicle, a manned spacecraft, an unmanned spacecraft, a manned rotorcraft, an unmanned rotorcraft, a manned ground vehicle, an unmanned ground vehicle, a manned surface vehicle, an unmanned surface vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

[0082] Article 18. A method (100) comprising: providing a co-curable composite substrate (102), the co-curable composite substrate including a composite substrate first side and a composite substrate second side; applying (104) a co-curable UV / visible light resistant fiberglass-containing layer onto the second side of the composite substrate, the co-curable UV / visible light resistant fiberglass-containing layer having a UV / visible light transmittance value in the range of about 0% to about 20% UV / visible light transmittance for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the curable UV / visible light resistant fiberglass-containing layer has an average thickness in the range of about 2 mils to about 6 mils; and and co-curing (106) the co-curable composite substrate with the co-curable UV / visible light resistant fiberglass-containing layer to form a co-cured composite assembly for an aircraft structure.

[0083] Article 19. 19. The method of clause 18, wherein the co-cured composite assembly does not include a UV / visible light resistant paint or a UV / visible light resistant primer layer.

[0084] Article 20. 19. The method of claim 18, wherein the co-curable UV / visible light resistant fiberglass-containing layer is applied to the co-curable composite substrate as a single ply.

[0085] Article 21. 19. The method of clause 18, wherein the co-curable composite substrate comprises a carbon fiber reinforced polymer composite substrate.

[0086] Article 22. 19. The method of claim 18, wherein the co-curable composite substrate comprises a fiber reinforced epoxy resin matrix, the fiber reinforced epoxy resin matrix comprising at least one of carbon fiber, boron fiber, aramid fiber, fiberglass fiber, polyester fiber, and combinations thereof.

[0087] The present aspect contemplates co-curable and co-cured UV / visible light resistant composite materials comprising a UV / visible light resistant fiberglass layer in intimate contact with a composite substrate (which may be, for example, a carbon fiber reinforced polymer substrate, or even an epoxy resin based composite substrate) in composite assemblies useful in the manufacture of vehicles and vehicle assemblies, including, for example, aircraft wing assemblies, horizontal stabilizer assemblies, vertical stabilizer assemblies, fuselages, fuel tanks within wing assemblies, nacelles, and other aircraft structures and structural components comprising composite materials.

[0088] The present aspects may, of course, be embodied in other ways than those specifically set forth herein without departing from the essential features of the disclosure. The examples herein are to be considered in all respects as illustrative and not restrictive, and all changes that come within the meaning and range of equivalency of the claims are intended to be embraced therein.

Claims

1. A co-curable composite material assembly (20a), A co-curable composite material substrate (22a), comprising a first side surface (22a') and a second side surface (22a'') of the co-curable composite material substrate, and A co-curable UV / visible light resistant fiberglass-containing layer (24a), comprising a first side surface (24a') of the co-curable UV / visible light resistant fiberglass-containing layer and a second side surface (24a'') of the co-curable UV / visible light resistant fiberglass-containing layer, The co-curable UV / visible light resistant fiberglass-containing layer is a co-curable composite material assembly having a UV / visible light transmittance value in the range of approximately 0% to approximately 20% for UV / visible light wavelengths in the range of approximately 200 nm to approximately 800 nm, when the co-curable UV / visible light resistant fiberglass-containing layer has an average thickness in the range of approximately 50.8 μm (2 mils) to approximately 152.4 μm (6 mils).

2. The co-curable composite material assembly according to claim 1, wherein the co-curable composite material substrate is co-curable with the co-curable UV / visible light resistant fiberglass-containing layer at a temperature in the range of approximately 250 degrees Fahrenheit to approximately 370 degrees Fahrenheit.

3. The co-curable composite material assembly according to claim 1, wherein the co-curable composite material substrate comprises a carbon fiber reinforced polymer.

4. The co-curable composite material assembly according to claim 1, wherein the co-curable composite material substrate comprises an epoxy resin compound, and the co-curable composite material substrate further comprises at least one of carbon fibers, boron fibers, aramid fibers, glass fibers, polyester fibers, and combinations thereof.

5. The co-curable composite material assembly according to claim 1, wherein the co-curable composite material substrate comprises a plurality of carbon fiber reinforced polymer prepregs.

6. The co-curable composite material assembly according to claim 1, wherein a second side surface of the co-curable composite material substrate is in direct contact with a first side surface of the co-curable UV / visible light resistant fiberglass-containing layer, and the co-curable UV / visible light resistant fiberglass-containing layer completely covers the second side surface of the co-curable composite material substrate.

7. A co-cured composite material assembly (20b), A co-cured composite material substrate (22b), comprising a first side surface (22b') and a second side surface (22b') of the composite material substrate, and A co-cured UV / visible light resistant fiberglass-containing layer (24b), comprising a co-cured UV / visible light resistant fiberglass-containing layer (24b) including a first side surface (24b') and a second side surface (24b'') of the co-cured UV / visible light resistant fiberglass-containing layer, The co-cured composite material substrate and the co-cured UV / visible light resistant fiberglass-containing layer are co-cured in a co-curing regime that includes a co-curing temperature in the range of approximately 250 degrees Fahrenheit to approximately 370 degrees Fahrenheit. The co-cured UV / visible light resistant fiberglass-containing layer is a co-cured composite material assembly having a UV / visible light transmittance value in the range of approximately 0% to approximately 20% for UV / visible light wavelengths in the range of approximately 200 nm to approximately 800 nm, when the co-cured UV / visible light resistant fiberglass-containing layer has an average thickness in the range of approximately 50.8 μm (2 mils) to approximately 152.4 μm (6 mils).

8. The co-cured composite material assembly according to claim 7, wherein the co-cured composite material substrate comprises a fiber-reinforced epoxy resin matrix, the fiber-reinforced epoxy resin matrix comprises at least one of carbon fibers, boron fibers, aramid fibers, glass fibers, polyester fibers, and combinations thereof.

9. The co-cured composite material assembly according to claim 7, wherein the co-cured composite material substrate comprises a plurality of carbon fiber reinforced polymer composite material prepregs.

10. The co-cured composite assembly according to claim 7, wherein the co-cured UV / visible light resistant fiberglass-containing layer is included in the co-cured composite assembly, thereby eliminating the need for at least one of a detail primer layer and a UV / visible light absorbing paint layer in the final co-cured composite assembly.

11. A structure comprising a co-cured composite material assembly according to claim 7, comprising an outer mold line of an aircraft wing assembly, wherein a second side of the co-cured UV / visible light resistant fiberglass-containing layer is configured to support at least one of the primer (26c)(26d) and the topcoat (28c)(28d) of the assembly.

12. A structure comprising a co-cured composite material assembly according to claim 7, the structure comprising at least one of an aircraft wing assembly (12), an aircraft horizontal stabilizer assembly (14), a vertical stabilizer assembly (16), and a combination thereof.

13. A structure (10) comprising a co-cured composite material assembly according to claim 7, the structure comprising an aircraft wing assembly.

14. A vehicle (10) including the structure described in claim 12.

15. A vehicle (10) including the structure described in claim 13.

16. The aforementioned vehicle, The vehicle according to claim 14, selected from the group consisting of manned aircraft, unmanned aircraft, manned spacecraft, unmanned spacecraft, manned rotary-wing aircraft, unmanned rotary-wing aircraft, manned ground vehicles, unmanned ground vehicles, manned water vehicles, unmanned water vehicles, manned underwater vehicles, unmanned underwater vehicles, artificial satellites, and combinations thereof.

17. The aforementioned vehicle, A vehicle according to claim 15, selected from the group consisting of manned aircraft, unmanned aircraft, manned spacecraft, unmanned spacecraft, manned rotary-wing aircraft, unmanned rotary-wing aircraft, manned ground vehicles, unmanned ground vehicles, manned water vehicles, unmanned water vehicles, manned underwater vehicles, unmanned underwater vehicles, artificial satellites, and combinations thereof.

18. Method (100), (102) To provide a co-curable composite material substrate, wherein the co-curable composite material substrate includes a first side surface of the composite material substrate and a second side surface of the composite material substrate. (104) Adding a co-curable UV / visible light resistant fiberglass-containing layer on the second side surface of the composite material substrate, wherein the co-curable UV / visible light resistant fiberglass-containing layer has an average thickness in the range of about 50.8 μm (2 mils) to about 152.4 μm (6 mils), and the UV / visible light resistant fiberglass-containing layer has a UV / visible light transmittance value in the range of about 0% to about 20% for UV / visible light wavelengths in the range of about 200 nm to about 800 nm, and A method for forming a co-cured composite material assembly for aircraft structures, comprising co-curing a co-curable composite material substrate with a co-curable UV / visible light resistant fiberglass-containing layer (106).

19. The method according to claim 18, wherein the co-cured composite material assembly does not include a UV / visible light resistant paint or a UV / visible light resistant primer layer.

20. The method according to claim 18, wherein the co-curable UV / visible light resistant fiberglass-containing layer is added to the co-curable composite material substrate as a single ply.

21. The method according to claim 18, wherein the co-curable composite material substrate includes a carbon fiber reinforced polymer composite material substrate.

22. The method according to claim 18, wherein the co-curable composite material substrate comprises a fiber-reinforced epoxy resin matrix, and the fiber-reinforced epoxy resin matrix comprises at least one of carbon fibers, boron fibers, aramid fibers, glass fibers, polyester fibers, and combinations thereof.

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