Composite material coated with co-cured UV / visible light resistant fiberglass for aircraft fuselage assembly

Abstract

To disclose a co-curable composite fuselage assembly.SOLUTION: An aircraft fuselage includes: a co-curable and co-cured UV / visible light resistant fiberglass-coated UV / visible light composite structural material substrate; and a co-cured UV / visible light resistant fiberglass-coated composite material substrate.SELECTED DRAWING: Figure 2A

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] 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.

[0004] 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.

[0005] 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

[0006] The present embodiment discloses co-curable and co-cured composites comprising a co-curable or co-cured layer of UV / visible light resistant fiberglass in direct contact with a co-curable or co-cured composite structural material substrate. The incorporation of the co-cured / co-curable UV / visible light resistant fiberglass layer into the co-cured / co-curable composite structural material substrate can significantly impact composite manufacturing, improving performance and reducing weight of composite structural materials by at least eliminating the need to include a separate UV / visible light resistant coating previously applied to the composite substrate, such as in preparing composite systems used in structural assemblies for larger components, including exterior and interior surfaces of vehicles, including aircraft.

[0007] According to this aspect, a co-curable composite fuselage assembly is disclosed. The co-curable composite fuselage assembly includes 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. As disclosed, the co-curable composite fuselage assembly further includes a co-curable UV / visible light resistant fiberglass-containing layer. The co-curable UV / visible light resistant fiberglass-containing layer includes a co-curable UV / visible light resistant fiberglass layer first side and a co-curable UV / visible light resistant fiberglass layer second side. The co-curable UV / visible light resistant fiberglass-containing layer has a UV / visible light transmittance value of 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. The co-curable composite (which may be, for example, a co-curable epoxy resin-based composite substrate, which may further be a co-curable carbon fiber reinforced polymer composite, etc.) combined with the co-curable UV / visible light resistant fiberglass-containing layer is configured to form a co-cured composite fuselage assembly, which may be a co-cured UV / visible light resistant fiberglass-containing composite fuselage assembly.

[0008] In another embodiment, the co-curable composite substrate is co-curable with a co-curable UV / visible light resistant fiberglass layer at a temperature ranging from about 250 degrees Fahrenheit to about 370 degrees Fahrenheit.

[0009] In yet another aspect, a co-curable composite substrate comprises a fiber reinforced epoxy resin-based matrix.

[0010] In another aspect, the co-curable composite substrate comprises at least one of carbon fibers, boron fibers, aramid fibers, fiberglass fibers, polyester fibers, and combinations thereof.

[0011] In another aspect, the co-curable composite substrate comprises a carbon fiber reinforced polymer.

[0012] In another aspect, a co-curable composite substrate includes a plurality of carbon fiber reinforced polymer prepregs.

[0013] In a further aspect, 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 layer, and the co-curable UV / visible light resistant fiberglass layer completely covers the second side of the co-curable composite substrate.

[0014] In another aspect, a co-curable composite substrate includes an exterior mold line.

[0015] In another aspect, a co-curable composite substrate is configured to form the skin or exterior surface of an aircraft fuselage assembly.

[0016] In a further aspect, the co-curable composite substrate includes an inner mold line.

[0017] In another aspect, a co-curable composite substrate is configured to form an interior or inner surface of an aircraft fuselage assembly.

[0018] In another aspect, a co-curable composite substrate includes both an outer mold line and an inner mold line.

[0019] In another aspect, a co-curable composite substrate is configured to form both an exterior or outer surface of an aircraft fuselage assembly and an interior or inner surface of the aircraft fuselage assembly.

[0020] According to another present aspect, a co-cured composite fuselage assembly is disclosed. The co-cured composite fuselage assembly includes a co-cured composite substrate. The co-cured composite substrate includes a co-cured composite substrate first side and a co-cured composite substrate second side. The co-cured composite fuselage assembly further includes a co-cured UV / visible light resistant fiberglass layer. The co-cured UV / visible light resistant fiberglass layer includes a co-cured UV / visible light resistant fiberglass layer first side and a co-cured UV / visible light resistant fiberglass layer second side. The first side of the co-cured UV / visible light resistant fiberglass layer is in direct contact with the second side of the co-cured composite substrate. The composite substrate and the co-cured UV / visible light resistant fiberglass layer are co-cured with a co-cure regimen to form the co-cured composite fuselage assembly. The co-cure regimen includes a co-cure temperature ranging from about 250°F to about 370°F. The co-cured UV / visible light resistant fiberglass layer has a UV / visible light transmittance value of 0% to about 20% for UV / visible light wavelengths ranging from about 200 nm to about 800 nm when the co-cured UV / visible light resistant fiberglass-containing layer has an average thickness ranging from about 2 mils to about 6 mils. The co-cured composite (which may be, for example, a co-curable epoxy resin-based composite substrate, which may further be a carbon fiber reinforced polymer composite, etc.) combined with the co-cured UV / visible light resistant fiberglass-containing layer is configured to form a co-cured composite fuselage assembly.

[0021] 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.

[0022] In another aspect, the inclusion of a UV / visible light resistant fiberglass-containing layer in a co-cured composite fuselage assembly eliminates the need for at least one of a detail primer layer and at least one spray surfacer when the composite fuselage assembly further includes a finished decorative color ring covering the co-cured composite fuselage assembly.

[0023] In a further aspect, the inclusion of a UV / visible light resistant fiberglass-containing layer in the co-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.

[0024] In another aspect, the co-cured composite substrate includes an exterior mold line.

[0025] In another aspect, the co-cured composite substrate is configured to form the skin or exterior surface of an aircraft fuselage assembly.

[0026] In a further aspect, the co-cured composite substrate includes an internal mold line.

[0027] In another aspect, the co-cured composite substrate is configured to form an interior or inner surface of an aircraft fuselage assembly.

[0028] In another aspect, a co-cured composite substrate includes both an outer mold line and an inner mold line.

[0029] In another aspect, the co-cured composite substrate is configured to form both the exterior or outer surface of an aircraft fuselage assembly and the interior or inner surface of the aircraft fuselage assembly.

[0030] In a further aspect, the co-cured composite substrate includes an exterior mold line on a first side of the co-cured composite, and the co-cured composite substrate further includes an interior mold line on a second side of the co-cured composite.

[0031] According to another aspect, a vehicle is disclosed that includes a co-cured composite fuselage assembly. The co-cured composite fuselage assembly further includes a co-cured composite substrate. 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 composite fuselage assembly further includes a co-cured UV / visible light resistant fiberglass layer. The co-cured UV / visible light resistant fiberglass layer includes a first side of the co-cured UV / visible light resistant fiberglass layer and a second side of the co-cured UV / visible light resistant fiberglass layer. The first side of the co-cured UV / visible light resistant fiberglass layer is in direct contact with the second side of the co-cured composite substrate. The composite substrate and the co-cured UV / visible light resistant fiberglass layer are co-cured with a co-curing regimen to form the co-cured composite fuselage assembly. The co-curing regimen includes a co-curing temperature ranging from about 250°F to about 370°F. The UV / visible light resistant fiberglass layer has a UV / visible light transmittance value of 0% to about 20% for UV / visible light wavelengths ranging from about 200 nm to about 800 nm when the co-cured UV / visible light resistant fiberglass-containing layer has an average thickness ranging from about 2 mils to about 6 mils. The co-cured composite (which may be, for example, a co-curable epoxy resin-based composite substrate, which may further be a carbon fiber reinforced polymer composite, etc.) combined with the co-cured UV / visible light resistant fiberglass-containing layer is configured to form a co-cured composite fuselage assembly.

[0032] In another 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.

[0033] In a further aspect, the vehicle is an aircraft.

[0034] According to a further present aspect, a method for making a co-cured composite aircraft fuselage is disclosed, the method including providing a co-curable composite substrate, the co-curable composite substrate including a co-curable composite substrate first side and a co-curable composite substrate second side.

[0035] The method further includes applying at least one co-curable UV / visible light resistant fiberglass layer onto at least one of the first side of the co-curable composite substrate and the second side of the co-curable composite substrate. The co-curable UV / visible light resistant fiberglass layer has a UV / visible light transmittance value of 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. The method further includes co-curing the co-curable composite substrate with the co-curable UV / visible light resistant fiberglass-containing layer and forming a co-cured composite fuselage assembly for an aircraft structure.

[0036] 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.

[0037] 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]

[0038] [Figure 1A] 1 is a diagram of a vehicle in the form of an aircraft according to present aspects; [Figure 1B] 1B is a cross-sectional view of a vehicle in the form of an aircraft shown in FIG. 1A according to a present embodiment. [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. 2 is an enlarged cross-sectional representative side view of a co-cured UV / visible light resistant composite stack according to the present embodiment. [Figure 3] 1 is a flowchart outlining a method according to the present embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0039] 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.

[0040] Additionally, paint removal processes that remove various paint coating layers from composite materials often damage protective surfacing layers applied to the composite material and layers applied below the paint coating layers, and can require significant resurfacing work once a paint coating layer is removed from the surface layer. 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 a composite surface during processing of the composite surface is also labor-intensive, time-consuming, and expensive.

[0041] During the manufacture of composite parts, which may include composite substrates that 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 (UV) / visible radiation. To avoid changes in the surface properties of the composite that 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.

[0042] Adding UV mitigants (e.g., UV "blockers") to composite surfaces as UV-blocking material layers often adds manufacturing complexity in ways that at least increase manufacturing time, increase rework time, increase overall production costs, etc., because the applied UV-blocking material covering is 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 further processed to receive subsequent paint layers or topcoats. This further processing of each subsequent layer added to the composite (which may be a composite "stack") again increases manufacturing time, increases rework time, increases overall production costs, etc.

[0043] 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 (UV) / visible light radiation during use of the composite as a building material in the manufacture of a larger structure.

[0044] 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.).

[0045] The present aspects are directed to 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 composite substrate. The incorporation of the co-cured and co-curable UV / visible light resistant fiberglass layer into a composite substrate can significantly impact composite manufacturing, improving structural composite performance and reducing weight by at least eliminating the need to include a series of separate UV-resistant coatings 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, for example, the interior and exterior surfaces of vehicles, including aircraft fuselages.

[0046] According to the present aspect, methods are disclosed for improving UV / visible light protection of composite substrates and substrate surfaces, reducing UV / visible light degradation, and forming co-cured composite substrates with improved UV / visible light protection without the previously required presence of typically added protective cover or primer layers or separate layers (e.g., UV-absorbing paints). 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 reduced composite stack complexity and overall composite stack weight, which further reduces composite processing time. The significant reduction in composite UV / visible light degradation can further reduce or delay the frequency of the need for composite rework (necessitated by such UV / visible light degradation).

[0047] 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.

[0048] Figure 1 is a diagram of a vehicle in the form of an aircraft according to the present embodiment. As shown in Figure 1A, aircraft 10 includes a wing assembly 12, an aircraft fuselage 13, a horizontal stabilizer assembly 14, and a vertical stabilizer assembly 16. Composite materials of the present disclosure can be configured to form a variety of vehicle and aircraft assemblies, including the one shown in Figure 1A.

[0049] Figure 1B is an enlarged cross-sectional view of the interior of the aircraft 10. Figure 1B further shows the aircraft fuselage 13, which includes an aircraft fuselage exterior 13a. The aircraft fuselage exterior 13a includes an outer mold line (OML). Figure 1B further shows the aircraft fuselage 13, which includes an aircraft fuselage interior 13b. The aircraft fuselage interior 13b includes an inner mold line (IML).

[0050] According to this aspect, there is provided a co-curable composite substrate that may comprise a composite material, which may be a co-curable epoxy resin-based composite material combined with a fiber matrix that may include carbon fiber, boron fiber, glass fiber, aramid fiber, polyester fiber, and combinations thereof. Co-curable carbon fiber is particularly preferred as the composite substrate, and co-curable carbon fiber reinforced polymer is especially preferred.

[0051] According to a further aspect of the present disclosure, the co-curable composite material used in the manufacture of the composite structure further comprises a co-curable UV / visible light resistant layer (equivalently referred to herein as a UV / visible light suppressive layer). The co-curable UV / visible light resistant layer is provided in the form of a co-curable UV / visible light resistant fiberglass layer, which may be a single fiberglass ply layer. According to a further aspect of the present disclosure, the co-curable UV / visible light resistant fiberglass layer is provided in intimate contact with the material of a co-curable composite substrate. The composite substrate is co-curable with the co-curable UV / visible light resistant fiberglass layer.

[0052] The composite substrate, also referred to herein as a base layer, underlayer, or composite substrate layer, can be a co-curable composite material, which can be an epoxy resin-based material. This includes fiber-reinforced polymer composites, which can have an epoxy resin-based matrix and can include carbon fiber-reinforced polymer composites. In this embodiment, the co-curable composite can be any suitable composite material that can be co-cured with a co-curable fiberglass-containing material at a temperature ranging from about 250°F to about 370°F.

[0053] Composite materials are often assembled 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.

[0054] According to this embodiment, a selected degree of UV / visible light resistance and UV / visible light protection is imparted to the composite substrate exclusively by directly contacting the co-curable composite surface with a co-curable UV / visible light resistant fiberglass layer that, after co-curing, forms 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 is rendered 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.

[0055] By co-curing the UV / visible light resistant fiberglass layer with the composite material, benefits are imparted by the co-cured UV / visible light resistant fiberglass layer of the present disclosure to a final assembly incorporating at least the underlying epoxy-based composite material and the co-cured UV / visible light resistant fiberglass coated composite substrate. According to this aspect, such imparted benefits include, but are not limited to, UV / visible light protection of the composite material and protection of the composite substrate from the deleterious effects of mechanical paint removal techniques.

[0056] Additionally, the robustness of the co-curable UV / visible light resistant fiberglass layer of the present disclosure, for example, co-cured onto a co-curable epoxy-based composite substrate, is selected to withstand subsequent and repeated heat treatments that may be required during subsequent and repeated repainting or rework protocols. That is, unlike some currently required repainting or rework 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. Furthermore, the present embodiment contemplates the removal or reconditioning of only the layer (e.g., topcoat layer, basecoat layer, clearcoat layer, intermediate coating layer, etc.) coated onto the co-cured UV / visible light resistant fiberglass layer of the present disclosure, if desired.

[0057] 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.

[0058] According to this embodiment, FIG. 2A shows an enlarged cross-sectional representative side view of a co-curable composite material assembly 20a comprising a co-curable composite substrate 22a (having a co-curable composite substrate first side 22a′ and a co-curable composite substrate second side 22a″) disposed thereon, the co-curable UV / visible light resistant fiberglass layer 24a (having a co-curable UV / visible light resistant fiberglass layer first side 24a′ and a co-curable UV / visible light resistant fiberglass layer second side 24a″). According to this embodiment, the co-curable composite material assembly 20a can be co-cured to form a co-cured composite material (as shown in FIGS. 2B and 2C). The co-curable composite material assembly 20a is subjected to a co-cure regimen. In a co-curing regimen, a co-curable UV / visible light resistant fiberglass layer 24a disposed on a co-curable composite substrate 22a is co-cured at a cure 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. As shown in FIG. 2A, the co-curable composite substrate 22a can be a co-curable carbon fiber reinforced polymer composite substrate and can also be a co-curable epoxy resin based composite substrate.

[0059] 2B illustrates a co-cured UV / visible light resistant composite material 20b formed from co-curing the uncured and co-curable components shown in FIG. 2A. In the co-cured state as shown in FIG. 2B, co-cured UV / visible light resistant fiberglass layer 24b (having co-cured UV / visible light resistant fiberglass layer 24b' and co-cured UV / visible light resistant fiberglass layer 24b") co-cured with co-cured composite substrate 22b (having co-cured composite substrate first side 22b' and co-cured composite substrate second side 22b") forms co-cured UV / visible light resistant composite material assembly 20b. According to this embodiment, 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 up to 100% to the underlying co-cured composite substrate 22b, whereby the co-cured UV / visible light resistant fiberglass layer 24b 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.

[0060] According to this embodiment, the UV / visible light resistant fiberglass layer is selected to have certain UV / visible light resistance properties and values. The co-cured UV / visible light resistant fiberglass layer is thereby solely responsible for imparting a certain degree (e.g., 100%) of UV resistance and UV / visible light protection to the underlying epoxy resin-based composite. That is, according to this embodiment, the UV blocking capability of the co-cured UV / visible light resistant fiberglass layer eliminates the need for, renders redundant, or otherwise unnecessary, any additional UV / visible light resistant layers within the composite "stack." These include, for example, UV / visible light resistant paint, UV / visible light resistant primer, and UV / visible light resistant topcoat "stacks." Similarly, this capability 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 material assemblies of the present disclosure and for structures incorporating the co-cured composite material 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, otherwise provided to the composite. Again, no additional UV / visible light resistant layer is required to achieve the desired UV / visible light blocking functionality for the co-cured composite assemblies of the present disclosure.

[0061] 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 fuselages. Thus, when configured as various aircraft structural composites, a co-cured UV / visible light resistant composite assembly 20b, including, for example, 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 an aircraft fuselage.

[0062] In addition, not only can a co-cured UV / visible light-resistant composite assembly 20b of the type shown in FIG. 2B be used as a structural composite for a fuselage exterior having a co-cured composite assembly with an exterior mold line (e.g., as shown in FIG. 1B for aircraft fuselage exterior 13a), but also a co-cured composite assembly 20b of the type shown in FIG. 2B can be used as a structural composite for a fuselage interior having a co-cured composite assembly with an interior mold line (e.g., as shown in FIG. 1B for aircraft fuselage exterior 13b). In accordance with this embodiment, the versatility of such composites allows composite fuselage interiors to be protected from exposure to harmful UV / visible light radiation. In a currently contemplated configuration, a co-cured UV / visible light-resistant fiberglass layer coats and protects a segment of a composite substrate disposed in an aircraft fuselage interior. Both sides of the composite substrate can include a co-cured UV / visible light-resistant fiberglass layer, thereby protecting both sides of the co-cured composite from the harmful effects of UV / visible light radiation exposure.

[0063] 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 composite system (equivalently referred to herein as a composite "stack") 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 with a co-cured UV / visible light resistant fiberglass layer 24c disposed thereon. 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).

[0064] As shown in FIG. 2C , co-cured UV / visible light resistant composite material assembly 20c further includes sol-gel 25c, intermediate coat layer 26c, and top coat layer 28c covering co-cured UV / visible light resistant fiberglass layer 24c. According to this embodiment, a co-cured composite material system useful for aircraft fuselages differs from typical material systems used to coat composite materials used in the manufacture of aircraft fuselages in that primer layer(s) are notably absent or otherwise unnecessary. This elimination of primer layer(s) can result in significant weight reduction, cost reduction, processing time reduction, rework time reduction, man-hour labor reduction, and reduced material requirements, depending on the scale of the large structures with large structural assemblies, including, for example, aircraft fuselages.

[0065] According to this embodiment, the co-cured UV / visible light resistant fiberglass layer provides multi-functionality to the composite system. The benefits of the fiberglass layer and the UV / visible light resistant layer are now combined into one intentionally co-cured, multi-functional co-cured fiberglass layer. It is also UV / visible light resistant, providing any needed UV / visible light protection to the underlying composite substrate while simplifying the preparation / manufacturing of composite systems used, for example, as aircraft fuselages. As shown in Figures 2B and 2C, the co-cured composite structures 22b, 22c can be co-cured carbon fiber reinforced polymer composite substrates or co-cured epoxy resin-based composite substrates.

[0066] Additionally, at least the type of co-cured UV / visible light resistant composite assembly 20b shown in FIG. 2B can be used as a structural composite for fuselage exteriors having co-cured composite assemblies with external mold lines (e.g., as shown in FIG. 1B for aircraft fuselage exterior 13a), and the type of co-cured composite assembly 20b shown in FIG. 2B can also be used as a structural composite for fuselage interiors having co-cured composite assemblies with internal mold lines (e.g., as shown in FIG. 1B for aircraft fuselage exterior 13b). In accordance with this embodiment, the versatility of such composites allows composite fuselage interiors to be protected from exposure to harmful UV / visible light radiation. In a currently contemplated configuration, a co-cured UV / visible light resistant fiberglass layer coats and protects a segment of a composite substrate disposed in an aircraft fuselage interior. Both sides of the composite substrate can include a co-cured UV / visible light resistant fiberglass layer, thereby protecting both sides of the co-cured composite from the harmful effects of UV / visible light radiation exposure.

[0067] 3 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.

[0068] As shown in FIG. 3 , 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 composite substrate. Method 100 further includes disposing a co-curable UV / visible light resistant fiberglass layer (104) on the co-curable composite substrate. According to this embodiment, the co-curable UV / visible light resistant fiberglass 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 Figure 2A and further described herein. The method 100 further includes co-curing 106 the co-curable 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 and 2C and described herein.

[0069] Furthermore, the present disclosure includes embodiments according to the following clauses:

[0070] Article 1. A co-curable composite fuselage 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"); the co-curable UV / visible light resistant fiberglass-containing layer has a UV / visible light transmittance value of 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; The co-curable composite substrate combined with the co-curable UV / visible light resistant fiberglass-containing layer is configured to form a composite fuselage assembly (20b)(20c).

[0071] Article 2. 10. The co-curable composite fuselage assembly of claim 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.

[0072] Article 3. 10. The co-curable composite fuselage assembly of claim 1, wherein the co-curable composite substrate comprises a fiber-reinforced epoxy resin matrix.

[0073] Article 4. 4. The co-curable composite fuselage assembly of clause 3, wherein the fiber reinforced epoxy resin matrix comprises at least one of carbon fibers, boron fibers, aramid fibers, fiberglass fibers, polyester fibers, and combinations thereof.

[0074] Article 5. 10. The co-curable composite fuselage assembly of claim 1, wherein the co-curable composite substrate comprises a carbon fiber reinforced polymer.

[0075] Article 6. 10. The co-curable composite fuselage assembly of claim 1, wherein the co-curable composite substrate comprises a plurality of carbon fiber reinforced polymer prepregs.

[0076] Article 7. A co-curable composite fuselage assembly as described in clause 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.

[0077] Article 8. 2. The co-curable composite fuselage assembly of clause 1, wherein the co-curable composite substrate includes an outer mold line (13a).

[0078] Article 9. 10. The co-curable composite fuselage assembly of claim 1, wherein the co-curable composite substrate includes an inner mold line (13b).

[0079] Article 10. 10. The co-curable composite fuselage assembly of claim 1, wherein the co-curable composite substrate includes both an outer mold line and an inner mold line.

[0080] Article 11. A co-cured composite fuselage assembly (20b), comprising: a co-cured composite substrate (22b), comprising a co-cured composite substrate first side (22b') and a co-cured composite substrate second side (22b'); and a co-cured UV / visible light resistant fiberglass layer (24b), the co-cured UV / visible light resistant fiberglass layer comprising a first side (24b') of the co-cured UV / visible light resistant fiberglass layer and a second side (24b") of the co-cured UV / visible light resistant fiberglass layer; a first side of the co-cured UV / visible light resistant fiberglass layer in direct contact with a second side of the co-cured composite substrate; the co-cured composite substrate and the co-cured UV / visible light resistant fiberglass layer are co-cured in a co-cure regimen to form a co-cured composite fuselage assembly; a co-cured composite fuselage assembly, wherein the co-cured UV / visible light resistant fiberglass layer has a UV / visible light transmittance value of 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 layer has an average thickness in the range of about 2 mils to about 6 mils.

[0081] Article 12. 12. The co-cured composite fuselage assembly of claim 11, wherein the co-cured composite substrate comprises a fiber reinforced resin matrix, the fiber reinforced resin matrix comprising at least one of carbon fibers, boron fibers, aramid fibers, fiberglass fibers, polyester fibers, and combinations thereof.

[0082] Article 13. 12. The co-cured composite fuselage assembly of clause 11, wherein the co-cured composite fuselage assembly is configured to form a fuselage skin (13a).

[0083] Article 14. 12. The co-cured composite fuselage assembly of claim 11, wherein the co-cured composite fuselage assembly is configured to form a fuselage interior (13b).

[0084] Article 15. 12. The co-cured composite fuselage assembly of claim 11, wherein the co-cured composite substrate includes at least one of an outer mold line and an inner mold line.

[0085] Article 16. A vehicle (10) including the co-cured composite fuselage assembly of clause 11.

[0086] Article 17. The vehicle is 17. The vehicle of clause 16 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.

[0087] Article 18. A method (100) comprising: providing a co-curable composite substrate (102), the co-curable composite substrate including a co-curable composite substrate first side and a co-curable composite substrate second side; applying (104) a co-curable UV / visible light resistant fiberglass-containing layer onto a second side of the co-curable composite substrate, the UV / visible light resistant fiberglass-containing layer having a UV / visible light transmittance value of 0% to about 20% for UV / visible light wavelengths in the range of about 200 nm to about 800 nm when the 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 fuselage assembly for an aircraft.

[0088] Article 19. 19. The method of clause 18, wherein the co-cured composite fuselage assembly is configured to form an aircraft fuselage skin.

[0089] Article 20. 19. The method of claim 18, wherein the co-cured composite fuselage assembly is configured to form an aircraft fuselage interior.

[0090] 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 fuselage 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 has a UV / visible light transmittance value of 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 50.8 μm (2 mils) to about 152.4 μm (6 mils). A co-curable composite material body assembly, wherein the co-curable composite material substrate combined with the co-curable UV / visible light resistant fiberglass-containing layer is configured to form a composite material body assembly (20b) (20c).

2. The co-curable composite material body 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 fuselage assembly according to claim 1, wherein the co-curable composite material substrate comprises a fiber-reinforced epoxy resin matrix.

4. The co-curable composite material fuselage assembly according to claim 3, wherein the fiber-reinforced epoxy resin matrix comprises at least one of carbon fibers, boron fibers, aramid fibers, fiberglass fibers, polyester fibers, and combinations thereof.

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

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

7. The co-curable composite body assembly according to claim 1, wherein the second side surface of the co-curable composite substrate is in direct contact with the 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 substrate.

8. The co-curable composite material body assembly according to claim 1, wherein the co-curable composite material substrate includes an outer mold line (13a).

9. The co-curable composite material fuselage assembly according to claim 1, wherein the co-curable composite material substrate includes an inner mold line (13b).

10. The co-curable composite material body assembly according to claim 1, wherein the co-curable composite material substrate includes both an outer mold line and an inner mold line.

11. A co-cured composite material fuselage assembly (20b), A co-cured composite material substrate (22b), comprising a first side surface (22b') and a second side surface (22b') of the co-cured composite material substrate, and A co-cured UV / visible light resistant fiberglass layer (24b), comprising a co-cured UV / visible light resistant fiberglass layer including a first side surface (24b') and a second side surface (24b'') of the co-cured UV / visible light resistant fiberglass layer, The first side surface of the co-cured UV / visible light resistant fiberglass layer is in direct contact with the second side surface of the co-cured composite material substrate. The co-cured composite substrate and the co-cured UV / visible light resistant fiberglass layer are co-cured in a co-curing regimen to form a co-cured composite body assembly. A co-cured composite body assembly wherein the co-cured UV / visible light resistant fiberglass layer has a UV / visible light transmittance value of 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 layer has an average thickness in the range of about 50.8 μm (2 mils) to about 152.4 μm (6 mils).

12. The co-cured composite material fuselage assembly according to claim 11, wherein the co-cured composite material substrate comprises a fiber-reinforced resin matrix, the fiber-reinforced resin matrix comprising at least one of carbon fibers, boron fibers, aramid fibers, fiberglass fibers, polyester fibers, and combinations thereof.

13. The co-cured composite material fuselage assembly according to claim 11, wherein the co-cured composite material fuselage assembly is configured to form a fuselage exterior (13a).

14. The co-cured composite fuselage assembly according to claim 11, wherein the co-cured composite fuselage assembly is configured to form a fuselage interior (13b).

15. The co-cured composite material fuselage assembly according to claim 11, wherein the co-cured composite material substrate includes at least one of an outer mold line and an inner mold line.

16. A vehicle (10) comprising a co-cured composite body assembly according to claim 11.

17. The aforementioned vehicle, A vehicle according to claim 16, 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 co-curable composite material substrate and a second side surface of the co-curable composite material substrate. (104) Adding a co-curable UV / visible light resistant fiberglass-containing layer on a second side surface of the co-curable composite material substrate, wherein the 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 has a UV / visible light transmittance value of 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 fuselage assembly for an aircraft, comprising co-curing a co-curable composite 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 fuselage assembly is configured to form an aircraft fuselage exterior.

20. The method according to claim 18, wherein the co-cured composite material fuselage assembly is configured to form an aircraft fuselage interior.

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