Co-curable and co-cured UV / visible light-resistant lightning strike protection materials for composite material assemblies

Abstract

To provide co-curable and co-cured UV / visible light-resistant composite material assemblies comprising a co-curable UV / visible light-resistant lightning strike protection layer that can facilitate and streamline manufacture of composite material assemblies and sub-assemblies, including exterior assemblies and sub-assemblies for aircraft, vehicles, and objects exposed to electromagnetic effects including lightning strikes.SOLUTION: A co-curable composite material assembly (20a) comprises: a co-curable composite material substrate (22a); a co-curable ultraviolet (UV) / visible light-resistant lightning strike protection layer (23a). The co-curable composite material substrate is co-curable with the co-curable UV / visible light-resistant lightning strike protection layer at a temperature ranging from about 250°F to about 370°F.SELECTED DRAWING: Figure 2A

Description

[Technical field]

[0001] The present disclosure relates generally to composite materials and composite assemblies used to manufacture large structural components, and more particularly, to the field of composite materials and composite assemblies used as structural materials for vehicles, including aircraft. [Background technology]

[0002] Composite materials are being increasingly used in the manufacture of various structural components, and due at least in part to their strength-to-weight ratio, composite materials offer the advantage of replacing denser materials such as metals, metal alloys, and the like, where the total weight of a completed structure (or the weight of a component part of a completed structure) is an important consideration in the selection of materials used in the manufacture of such a completed structure or parts of a completed structure.

[0003] Coating layers applied to composite materials often do not have the same durability or life span as the composite material to which they are applied. Composite material assemblies may otherwise include exterior or interior layers that may include, for example, protective or other coating layers. For example, when composite materials are used in the manufacture of vehicles, including, for example, aircraft, the exterior coatings, referred to as the "livery" of the aircraft, may require modification, rework, change of logos, designs, color schemes, and the like over the life of the vehicle. Such livery modifications may include, for example, the removal of one or more decorative coating layers applied to the composite material, including, for example, one or more paint layers. However, the removal of one layer or one layer type (paint layer, primer layer, adhesion promoter layer, adhesive layer, etc.) from materials laminated onto the composite material may require the removal of additional layers or layer types that then need to be reworked or rebuilt. Additionally, touch-up or other rework of livery that requires removal of the livery using livery removal techniques can damage the underlying layers or even the composite (e.g., if the composite is subjected to excessive mechanical livery removal techniques).

[0004] Additionally, composite parts made from composite materials used in the manufacture of larger structures (e.g., aircraft, etc.) may be exposed to electromagnetic effects (EME) during operation, including, but not limited to, lightning, static electricity buildup, etc. When such structures are exposed to EME, electrical currents conducted through the structures may damage dielectric materials (e.g., insulating materials) passing through the structures, including, for example, composite substrate structural materials and insulating coatings on composite substrate structural materials.

[0005] Unless expressly stated to be prior art, statements in this specification are not admitted to be prior art merely by virtue of their inclusion in the Technical Field and / or Background Sections. Summary of the Invention

[0006] Aspects of the present disclosure relate to co-cured composites and co-cured composites including a co-cured layer of a UV / visible light lightning protection material layer to form a co-cured composite assembly including a co-cured UV / visible light lightning protection layer, or a co-cured composite including a co-cured layer of a UV / visible light lightning protection material layer to form a co-cured composite assembly including a co-cured UV / visible light lightning protection layer. Aspects of the present disclosure further include incorporating a second co-cured UV / visible light light resistant material into the co-cured composite assembly including the co-cured UV / visible light lightning protection layer. Incorporating a co-cured UV / visible light resistant layer and a co-cured UV / visible light light resistant lightning protection material layer into a co-cured composite structural material substrate, or incorporating a co-cured UV / visible light resistant layer and a co-cured UV / visible light light resistant lightning protection material layer into a co-cured composite structural material substrate, can significantly impact composite manufacturing, improve performance, and reduce the weight of structural composites, for example, by at least eliminating the need to include separate UV / visible light resistant coatings, paints, primers, etc. that were previously applied to the composite substrate, such as, for example, in preparing composite systems used in structural assemblies for large parts, including, for example, interior and exterior surfaces of vehicles, including aircraft.

[0007] According to an aspect of the present disclosure, a co-curing composite assembly is disclosed that includes a co-curing composite substrate and a co-curing ultraviolet (UV) / visible light lightning resistant protective layer, wherein the co-curing composite substrate can be co-cured with the co-curing UV / visible light lightning resistant protective layer at a temperature ranging from about 250°F to about 370°F.

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

[0009] In other embodiments, the co-curable composite substrate comprises an epoxy resin-based compound, and the co-curable composite substrate further comprises at least one of carbon fibers, boron fibers, aramid fibers, glass fibers, polyester fibers, and combinations thereof.

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

[0011] In a further embodiment, the co-curable composite substrate is in direct contact with and immediately adjacent to the co-cured UV / visible light lightning resistant protective layer.

[0012] In other embodiments, the co-curable composite assembly includes a second co-curable UV / visible light resistant layer as a separate layer within the co-curable composite assembly.

[0013] In a further aspect, at least one of the co-cured UV / visible light resistant lightning protection layer and the second co-cured UV / visible light resistant layer comprises at least one of glass fiber, carbon fiber, polyester fiber, aramid fiber, quartz, and combinations thereof.

[0014] In another embodiment, at least one of the co-cured UV / visible light lightning resistant protective layer and the second co-cured UV / visible light resistant layer is a co-cured UV / visible light resistant fiberglass containing layer.

[0015] In other embodiments, the co-cured composite material assembly includes a co-cured UV / visible light resistant layer as a separate layer, the co-cured UV / visible light resistant layer includes both a second co-cured UV / visible light resistant layer and a co-cured UV / visible light light resistant lightning protection layer in a single material layer, and the co-cured composite material assembly may be co-cured at a temperature ranging from about 250°F to about 370°F.

[0016] In other embodiments, a second co-cured UV / visible light resistant layer is located proximate to the co-cured material substrate, and the second co-cured UV / visible light resistant layer is further configured to be located between the co-cured composite material substrate and the co-cured UV / visible light resistant lightning protection layer.

[0017] In another embodiment, a co-cured UV / visible lightning resistant protective layer is applied to a co-cured composite substrate as a single ply.

[0018] In another embodiment, a co-cured UV / visible light lightning resistant protective layer is applied as a single ply to a second co-cured UV / visible light resistant layer.

[0019] In other embodiments, a second co-cured UV / visible light resistant layer is applied to the co-cured composite substrate as a single ply.

[0020] A further aspect of the present disclosure is a co-cured composite assembly comprising a co-cured composite substrate and a co-cured ultraviolet (UV) / visible light lightning resistant protective layer, the co-cured UV / visible light lightning resistant protective layer having a UV / visible light transmittance value ranging from about 0% to about 20% UV / visible light transmission for UV / visible light wavelengths ranging from about 200 nm to about 800 nm when the co-cured UV / visible light lightning resistant protective layer has an average thickness ranging from about 2 mils to about 6 mils. 7 Siemens / meter to 6.4 x 10 7 It relates to a co-cured composite assembly having electrical conductivity in the Siemens / meter range.

[0021] In other embodiments, the co-cured composite substrate may be co-cured with a co-curable UV / visible lightning resistant protective layer at a temperature ranging from about 250°F to about 370°F.

[0022] In a further embodiment, the co-cured composite substrate comprises a carbon fiber reinforced polymer.

[0023] In other embodiments, the co-cured composite substrate comprises an epoxy resin-based compound, and the co-cured composite substrate further comprises at least one of carbon fibers, boron fibers, aramid fibers, glass fibers, polyester fibers, and combinations thereof.

[0024] In another embodiment, the co-cured composite substrate is in direct contact with and immediately adjacent to the co-cured UV / visible light lightning resistant protective layer.

[0025] In a further embodiment, an assembly primer layer is disposed over the co-cured UV / visible light lightning resistant protective layer, and the co-cured composite assembly further includes a topcoat layer disposed over the assembly primer layer.

[0026] In another embodiment, a definition primer layer is disposed between the co-cured UV / visible light shock resistant protective layer and the primer layer.

[0027] In a further embodiment, the co-cured composite assembly further comprises a second co-cured UV / visible light resistant layer, and both the second co-cured UV / visible light resistant layer and the co-cured UV / visible light light resistant lightning protection layer are co-cured with the co-cured composite substrate.

[0028] In other embodiments, a second co-cured UV / visible light resistant layer is located between the co-cured composite substrate and the co-cured UV / visible light lightning resistant protective layer.

[0029] In other embodiments, the co-cured composite assembly further comprises an assembly primer layer disposed on the co-cured UV / visible light lightning resistant protective layer, and the co-cured composite assembly further comprises a topcoat layer disposed on the assembly primer layer.

[0030] In another embodiment, the co-cured composite assembly further comprises a definition primer layer disposed between the assembly primer layer and the co-cured UV / visible light lightning resistant protective layer.

[0031] In a further embodiment, a co-cured UV / visible light lightning resistant protective layer is located between the co-cured composite substrate and the second co-cured UV / visible light resistant layer.

[0032] In other embodiments, the co-cured UV / visible light lightning resistant protective layer is located between the co-cured composite substrate and the second co-cured UV / visible light light resistant layer, the co-cured composite assembly further comprising an assembly primer layer disposed on the second co-cured UV / visible light lightning resistant layer, and the co-cured composite assembly further comprising a topcoat layer disposed on the assembly primer layer.

[0033] In other embodiments, the co-cured UV / visible light lightning resistant protective layer is located between the co-cured composite substrate and the second co-cured UV / visible light resistant layer, the co-cured composite assembly further includes a definition primer layer disposed on the second co-cured UV / visible light resistant layer, and the co-cured composite assembly further includes a topcoat layer disposed on the assembly primer layer, the definition primer layer optionally being disposed between the assembly primer layer and the second co-cured UV / visible light resistant layer.

[0034] In other embodiments, the second co-cured UV / visible light resistant layer is a separate layer within the co-cured composite assembly.

[0035] In a further aspect, at least one of the co-cured UV / visible light lightning resistant protective layer and the second co-cured UV / visible light resistant layer comprises at least one of glass fiber, carbon fiber, polyester fiber, aramid fiber, quartz, and combinations thereof.

[0036] In another embodiment, at least one of the co-cured UV / visible light lightning resistant protective layer and the co-cured UV / visible light resistant layer is a co-cured UV / visible light resistant fiberglass-containing layer.

[0037] In another embodiment, a co-cured UV / visible lightning resistant protective layer is co-cured into the co-cured composite assembly as a single ply.

[0038] In other embodiments, a second co-cured UV / visible light resistant layer is co-cured as a single ply within the co-cured composite assembly.

[0039] According to a further aspect of the present disclosure, a vehicle comprises the co-cured composite assembly, the vehicle being 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.

[0040] According to a further aspect of the present disclosure, a method of making a co-curable composite assembly is disclosed, the method including providing a co-curable composite substrate and disposing a co-curable ultraviolet (UV) / visible light lightning protection layer on the co-curable composite substrate to form a co-curable composite lightning protection assembly, wherein the co-curable composite substrate may be co-cured with the co-cured ultraviolet (UV) / visible light lightning protection layer at a temperature in the range of about 250° F. to about 370° F.

[0041] In another embodiment, the method further comprises disposing a co-curable UV / visible lightning resistant protective layer in close proximity to the co-curable composite substrate.

[0042] In a further embodiment, the method further comprises providing a co-curable UV / visible light resistant glass fiber-containing layer to the co-curable composite assembly.

[0043] In another embodiment, the method further comprises disposing a co-cured UV / visible light resistant glass fiber-containing layer between the co-cured composite substrate and the co-cured UV / visible light lightning resistant protective layer.

[0044] In another embodiment, the method further includes disposing a co-cured UV / visible light resistant lightning protection layer between the co-cured composite substrate and the co-cured UV / visible light resistant glass fiber-containing layer in the co-cured composite lightning protection assembly.

[0045] In a further embodiment, the method further comprises co-curing the co-curable composite lightning protection assembly at a temperature ranging from about 250° F. to about 370° F. to form a co-cured composite assembly, wherein the co-cured UV / visible lightning resistant protective layer has a viscosity of 2×10 7 Siemens / meter to 6.4 x 10 7 It has a conductivity in the Siemens / meter range.

[0046] The above-described features, functions, and advantages can be realized alone in various aspects or can be combined in yet other aspects, which aspects can be more fully understood by referring to the following specification and the accompanying drawings.

[0047] Having generally described the present disclosure in terms of variants, reference is now made to the accompanying drawings, which are not necessarily drawn to scale. [Brief description of the drawings]

[0048] [Figure 1] FIG. 1 is a diagram of a vehicle in the form of an aircraft in accordance with an aspect of the present disclosure. [Figure 2A] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 2B] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 3A] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 3B] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 4A]FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 4B] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 5A] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 5B] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 6A] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 6B] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 7] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible light resistant composite structure according to an embodiment of the present disclosure. [Figure 8] FIG. 2 is an enlarged cross-sectional view of a co-cured UV / visible composite structure according to an embodiment of the present disclosure. [Figure 9A] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 9B] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 10A] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 10B] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 11A] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 11B] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 12A] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 12B] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 13] FIG. 1 is a flow diagram outlining a method according to the present embodiment. [Figure 14] FIG. 1 is a flow diagram outlining a method according to the present embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0049] According to aspects of the present disclosure, a co-curable layer of material may be applied to a surface of a composite substrate and co-cured with the surface, for purposes that may include modifying the properties of a composite assembly, e.g., as a coating, an applied layer, an applied film layer, etc. Additionally, to improve adhesion of a subsequent coating layer, e.g., a paint, a topcoat, etc., a primer or other coating layer may be added to the composite material to provide a composite surface that may already have one or more other co-curable layers applied to the co-curable composite substrate.

[0050] Previously, layering of coating materials onto composite surfaces was laborious and time-consuming, and could add significant weight to large objects and structures that include such composites with multiple coating layers. In addition, the paint removal process of removing various paint coating layers from a composite material can often damage protective surface layers that may be applied to the composite material and that may be applied underneath the paint coating layers and that may require significant resurfacing once the paint layers are stripped from the surface layers. For example, each of one or more composite coating layers may require separate surfacing preparation steps and procedures, after which one or more coating layers are subsequently deposited on the composite surface. In some instances, it may be necessary to remove or otherwise rework portions of one or more previously deposited coatings before adding additional coating layers. Such intermediate reworking of composite surfaces during processing of the composite surfaces is also laborious, time-consuming, and costly.

[0051] For example, during the fabrication of composite parts, which may include epoxy resin-based composite materials (which may include, for example, carbon fiber reinforced polymer materials, etc.), the composite surface may begin to degrade at the composite surface even during manufacturing due to exposure to ambient ultraviolet (UV) / visible light radiation. To prevent changes in the surface properties of the composite material, which may be caused at least in part by exposure of the composite material to UV / visible radiation, the composite surface is often protected with a polymer coating or coated with at least one protective layer, such as, for example, a sprayed surface, a primer layer, etc., where the protective layer contains, for example, a UV "blocking" agent.

[0052] For example, composite materials are typically post-processed or "reworked" to repaint and / or resurface them. For example, a primer and paint coating containing a UV mitigating, or UV "cutting, "agent may be applied to the composite surface to protect the composite surface from degradation and / or discoloration that may be caused by exposure of the composite to ultraviolet (UV) / visible light radiation during use of the composite material as a building block in the manufacture of a large structure.

[0053] When a layer of UV mitigation or UV "cut" agents is applied to a composite surface, such applied coatings of UV-cutting material are typically removed or chemically or mechanically reactivated from the composite before additional composite assembly processing occurs, often increasing manufacturing complexity in the form of at least increased manufacturing time, increased rework time, increased total manufacturing costs, etc. In addition, primer and surfacing film layers are often treated to accept subsequent paint layers or topcoats. Such processing of individual subsequent layers (which may be layers arranged in a "stack" on a composite substrate) that are added to a composite system (also referred to herein as a "lamination system," an "assembly system," or a "system") also leads to increased manufacturing time, increased rework time, increased total manufacturing costs, etc.

[0054] Additionally, during aircraft manufacture and use, composite materials may require reworking of materials due to UV / visible light damage from UV / visible light wavelengths that affect coating layers and / or underlying composite materials used to coat the composite materials. Exposure to UV / visible light radiation may change material properties over time (e.g., during the life of a part, etc.). For example, UV / visible light radiation may make a coating layer or composite material vulnerable to processing damage, for example, when the layer or composite material is subjected to mechanical paint removal techniques, etc. Selection of material layers for large structures to protect against environmental hazards, including UV / visible light damage, may require the application of a series of coating layers, each of which may result in significant time, expense, and additional weight to large structures, including, for example, aircraft (weight concerns may further affect fuel use, cargo and passenger capacity, aircraft range, etc.).

[0055] Additionally, some coatings (e.g., paints, primers, etc.) are often electrically insulating (e.g., including dielectric materials) and may impede the dissipation of static and other charges. However, certain structures require dissipation of charges, including static charges, that build up on the interior and / or exterior surfaces of the structure and charges resulting from, for example, lightning strikes, etc. The need for dissipation of charges becomes increasingly important in the aircraft industry as aircraft manufacturing continues to incorporate non-metallic materials. Additionally, in certain aircraft assemblies, non-metallic materials that do not readily dissipate charge across their surfaces as expected, such as composites, plastics, etc., may be joined or otherwise in contact with assemblies and subassemblies that include metallic materials that conduct and move charge as expected. That is, parts, assemblies, and subassemblies that include both composites and metallic materials may be used during the manufacture of, or incorporated into, a larger structure (e.g., an aircraft).

[0056] Such structures may be exposed to electromagnetic effects (EME), including, by way of example and not limitation, lightning strikes. When a structure is exposed to EME, charge transferred to the structure will travel through any conductive path. Correspondingly, if a structure that includes insulating materials (e.g., dielectric materials) does not provide a conductive path for the generated EME, the current from the EME may cause substantial damage to the insulating materials, which may be, for example, composite materials.

[0057] Aspects of the present disclosure are directed to co-cured composite assemblies including a co-cured UV / visible light lightning resistant protective layer that is co-cured with a co-cured composite substrate to form a co-cured UV / visible light lightning resistant protective composite assembly, and a co-cured composite assembly including a co-cured UV / visible light lightning resistant protective layer. The incorporation of the co-cured UV / visible light lightning resistant protective layer into the co-cured composite substrate significantly impacts the composite manufacturing process, improves the performance of the co-cured composite assemblies (and larger structures including the co-cured composite assemblies), and reduces the weight of the composite assemblies, at least by eliminating the need to include a separate UV resistant coating that was previously applied to the composite substrate during formation of the composite assemblies, such as to protect the composite assemblies from UV / visible light damage both during composite manufacturing and during use of the composite assemblies, and during preparation of composite systems used in structural assemblies for large components including interior and exterior surfaces of vehicles, including aircraft. As used herein, the terms co-cured UV / visible light resistant composite "system" and co-cured UV / visible light resistant composite "assembly" are used equivalently.

[0058] According to aspects of the present disclosure, methods are disclosed for improving UV / visible light protection and reducing UV / visible light degradation of a composite substrate surface without the previously present protective coating or primer layer or separate layer of, for example, a UV absorbing paint, as well as a composite substrate with improved UV / visible light protection. In addition to preventing UV / visible light degradation of the underlying composite substrate surface, the methods, systems, and apparatus disclosed herein eliminate the need for protective coatings, protective primer layers, and UV absorbing paint layers, resulting in reduced complexity and reduced overall weight of the composite system, which further reduces composite processing time. Reducing UV / visible light degradation of the composite further reduces the need for planned or unplanned rework of the composite (e.g., previously required due to such UV / visible light degradation).

[0059] According to aspects of the present disclosure, there is provided a co-curing composite substrate that may include an epoxy resin-based composite in combination with a fiber matrix that may include carbon fiber, boron fiber, aramid fiber, glass fiber, polyester fiber, and combinations thereof, where carbon fiber is particularly desirable as a composite substrate, and carbon fiber reinforced polymer is particularly desirable as a composite substrate.

[0060] According to a further aspect disclosed herein, the co-cured composite material used in the manufacture of the composite structure further comprises a co-cured UV / visible lightning resistant protective layer (equivalently referred to as a co-cured UV / visible light suppressive lightning protective layer), where the co-cured UV / visible lightning resistant protective layer is in the form of a layer that may include a conductive material in combination with a non-conductive material. The conductive material may be or may otherwise include metallic materials that may be in expanded, braided, solid, and / or woven form of the type that may be used in lightning protective layers incorporated into large structures, including aircraft.

[0061] According to aspects of the present disclosure, a conductive material can be combined with a co-cured UV / visible light resistant material to form a co-cured UV / visible light lightning resistant protective material layer, which can be applied in layers that can be applied as individual layer plies or can be applied in multiple plies. Additionally, the co-cured UV / visible light lightning resistant protective material layer can be applied as a film. The co-cured UV / visible light lightning resistant protective material layer can include fiber-containing materials or other materials with a resin matrix, such as, for example, glass fiber, carbon fiber, polyester fiber, aramid fiber, and combinations thereof. In a further aspect, the co-cured UV / visible light lightning resistant protective material layer can include quartz-containing materials with a resin matrix.

[0062] According to an aspect of the present disclosure, the co-cured UV / visible light lightning-resistant protective material layer is disposed in the composite assembly such that the co-cured UV / visible light lightning-resistant protective material layer is in intimate contact with the co-cured composite substrate. In another aspect, the co-cured UV / visible light lightning-resistant protective material layer is disposed in the composite assembly such that the co-cured UV / visible light lightning-resistant protective material layer is disposed on top of the second co-cured UV / visible light light lightning-resistant protective material layer, and the second co-cured UV / visible light light lightning-resistant protective material layer is disposed in the composite assembly between the co-cured composite substrate and the co-cured UV / visible light light lightning-resistant protective material layer. Furthermore, the second co-cured UV / visible light light light resistant layer may also be applied as a film. The second co-cured UV / visible light light light resistant layer may include a fiber-containing material or other material with a resin matrix, such as, for example, glass fiber, carbon fiber, polyester fiber, aramid fiber, and combinations thereof. In a further embodiment, the second co-cured UV / visible light resistant layer may include a quartz-containing material with a resin matrix.

[0063] A co-curable composite substrate, also referred to herein as a "co-curable substrate base layer," or a "co-curable underlayer," or a "co-curable composite substrate layer," may be a co-curable composite material, which may be an epoxy resin-based material, including a fiber reinforced polymer composite material, which may have an epoxy resin-based matrix, and may include carbon fiber, boron fiber, aramid fiber, glass fiber, polyester fiber, and combinations thereof, where carbon fiber is particularly desirable as a co-curable composite substrate, and carbon fiber reinforced polymer is particularly desirable as a composite substrate.

[0064] In a further aspect of the present disclosure, the co-curable composite substrate can be any suitable composite that can be co-cured with the co-curable UV / visible light lightning protection layer and, if present, the second co-curable UV / visible light material layer at a temperature ranging from about 250° F. to about 370° F.

[0065] In another aspect of the present disclosure, the co-cured UV / visible light lightning resistant protective layer and, if present, the second co-cured UV / visible light material layer are configured to be co-cured in a co-cure regime, the co-cure regime including a co-cure temperature ranging from about 250° F. to about 370° F., and one or more of the co-cured UV / visible light lightning resistant protective layer and the second co-cured UV / visible light resistant layer have UV / visible light transmittance values ​​of about 0% to about 20% UV transmission for UV / visible light wavelengths ranging from about 200 nm to about 800 nm when the co-cured UV / visible light resistant glass fiber-containing layer has an average thickness ranging from about 2 mils to about 6 mils.

[0066] Composite materials are often layered into a laminate with a selected number of composite plies, often referred to as a "prepreg." A prepreg can be a "pre-impregnated" composite fiber with a matrix material already present, such as an epoxy resin-based material. The fibers are often in the form of a fabric, and a matrix is ​​used to hold them together into other components during manufacturing. Composite matrix materials are typically partially cured to allow for easy handling. Such composite matrix materials may require refrigerated or low temperature storage to prevent further partial or complete curing, and such composite matrix materials are referred to as B-stage materials. B-stage prepregs are then stored in a refrigerated area, as the ambient heat accelerates complete polymerization. Prepregs also impregnate a large amount of fiber, allowing the prepreg to be stored in a refrigerated area for extended periods of time before later curing. Prepregs are typically formed on a flat, workable surface. A stack of prepreg plies may then be formed thereon and, if desired, shaped into a desired shape using a molding or forming tool (also referred to as a mandrel). Aspects of the present disclosure contemplate, without limitation, the formation of co-curable and co-cured composite substrates utilizing the use of laid-up layers of composite prepregs.

[0067] According to aspects of the present disclosure, a "co-curable" material is defined as a material that may be co-cured with another material, such that the two co-curable materials will co-cure when subjected to common curing conditions, such as may be imposed by a predetermined curing regime (predetermined temperature, pressure, elevated temperature / rate, dwell period, etc.) to form a "co-cured" composition and / or co-cured material assembly.

[0068] According to aspects of the present disclosure, a selected degree of UV / visible light resistance and protection can be provided solely to the composite substrate by directly contacting the co-cured composite substrate with a co-cured UV / visible light lightning protection layer and / or a second UV / visible light light resistant layer (which can be, for example, a fiberglass containing layer) (which, after co-curing, forms a co-cured UV / visible light resistant composite assembly), i.e., aspects of the present disclosure can eliminate and / or significantly reduce the presence and / or application of previously required UV / visible light resistant primers, UV cut coatings, and the like. This is because the UV / visible light protection function within the UV / visible light resistant composite can be fulfilled exclusively by the additional placement of a co-cured UV / visible light resistant lightning protection layer disclosed herein (equivalently referred to herein as a "co-cured LSP layer"), alone or in combination with a second co-cured UV / visible light resistant layer, where the co-cured LSP layer is provided in direct contact with the co-cured composite substrate, or where the co-cured LSP layer is disposed on top of the second co-cured UV / visible light resistant layer when the second co-cured UV / visible light resistant layer is disposed in direct contact with the co-cured composite substrate.

[0069] By co-curing a co-cured UV / visible light lightning resistant protective layer with a co-cured composite substrate, benefits are provided by the co-cured UV / visible light lightning resistant protective layer disclosed herein to at least the underlying co-cured epoxy-based composite substrate and the entire co-cured composite assembly, as well as to any material and / or structure incorporating the co-cured composite substrate and the co-cured composite assembly, according to aspects of the present disclosure, including, but not limited to, protection of the epoxy-based composite from UV / visible light and protection of the composite substrate from, for example, the deleterious effects of mechanical paint removal techniques.

[0070] Additionally, the robustness of the co-cured UV / visible light lightning resistant protective layers disclosed herein, e.g., co-cured on and / or with the co-cured epoxy-based composite substrate, allows them to withstand subsequent repeated heat treatments that may be necessary during subsequent repeated repair protocols. That is, unlike some currently required repair protocols, the co-cured UV / visible light lightning resistant protective layers described herein do not need to be replaced, removed, or reapplied during rework, stripping, repainting, repeated heat treatments, etc. Aspects of the present disclosure contemplate removing, reconditioning, reworking, etc., when necessary, only the layers coated on the co-cured composite assemblies disclosed herein, e.g., topcoat layers, basecoat layers, clearcoat layers, intermediate coating layers, etc.

[0071] Through the use of the co-cured composite assemblies disclosed herein incorporating a co-cured UV / visible light lightning resistant protective layer to form a co-cured UV / visible light lightning resistant protective layer, a significant number of procedural steps previously required during repair or rework of a composite substrate are eliminated, resulting in substantial reductions in, for example, material costs to replace UV / visible light damaged layers, manpower resource time previously required for individual layer laydown processes (e.g., including individual layer pre-processing surface finishing steps, layer laydown steps, layer post-processing surface finishing steps (including chemical application, physical surface finishing processes (such as polishing, inspection of deposited layers, etc.)) resources).

[0072] Figure 1 is a diagram of a vehicle in the form of an aircraft according to an embodiment of the present disclosure. As shown in Figure 1, aircraft 10 includes a fuselage 11, a wing assembly 12, a horizontal stabilizer assembly 14, and a vertical stabilizer assembly 16, with co-cured composite assemblies disclosed herein configured to form various aircraft assemblies, including, for example, those shown in Figure 1.

[0073] FIG. 2A is an enlarged representative cross-sectional view of a co-cured UV / visible light resistant composite assembly 20a of a type usable as a structural assembly for an aircraft, including, for example, the exterior surface of the aircraft, according to an embodiment of the present disclosure, where the co-cured UV / visible light resistant composite assembly 20a includes a co-cured UV / visible light lightning resistant protective layer 23a disposed or positioned in close proximity to a co-cured composite substrate 22a.

[0074] As further shown in FIG. 2A, the co-cured composite assembly 20a further includes a second co-cured UV / visible light resistant layer 24a. As shown in FIG. 2A, the co-cured composite substrate 22a has a co-cured composite substrate first side 22a' and a co-cured composite substrate second side 22a". The co-cured UV / visible light lightning resistant protective layer 23a has a co-cured UV / visible light lightning resistant protective layer first side 23a' and a co-cured UV / visible light lightning resistant protective layer second side 23a". In addition, the second co-cured UV / visible light resistant layer 24a has a second co-cured UV / visible light resistant layer first side 24a′ and a second co-cured UV / visible light resistant layer second side 24a″. As shown in FIG. 2A , the co-cured UV / visible light resistant lightning protection layer 23a is disposed between the co-cured composite substrate 22a and the second co-cured UV / visible light resistant layer 24a.

[0075] FIG. 2B is an enlarged representative cross-sectional view of a co-cured UV / visible light resistant composite assembly 20b of the type usable (and shown in an uncured state in FIG. 2A ) as a structural assembly for an aircraft, including, for example, the exterior surface of the aircraft, according to an embodiment of the present disclosure, where the co-cured UV / visible light resistant composite 20b includes a co-cured UV / visible light lightning resistant protective layer 23b disposed or positioned in close proximity to a composite substrate 22b.

[0076] As further shown in FIG. 2B, the co-cured composite assembly 20b further includes a second co-cured UV / visible light resistant layer 24b. As shown in FIG. 2B, the co-cured composite substrate 22b has a co-cured composite substrate first side 22b' and a co-cured composite substrate second side 22b". The co-cured UV / visible light lightning resistant protective layer 23b has a co-cured UV / visible light lightning resistant protective layer first side 23b' and a co-cured UV / visible light lightning resistant protective layer second side 23b". Additionally, the second co-cured UV / visible light resistant layer 24b has a second co-cured UV / visible light resistant layer first side 24b' and a second co-cured UV / visible light resistant layer second side 24b". As shown in FIG. 2B, a co-cured UV / visible light light resistant lightning protection layer 23b is disposed between the co-cured composite substrate 22b and the second co-cured UV / visible light resistant layer 24b.

[0077] FIG. 3A is an enlarged representative cross-sectional view of a co-cured UV / visible light resistant composite assembly 30a of a type usable as a structural assembly for an aircraft, including, for example, the exterior surface of the aircraft, according to an embodiment of the present disclosure, where the co-cured UV / visible light resistant composite assembly 30a includes a co-cured UV / visible light lightning resistant protective layer 23a and a second UV / visible light resistant layer 24a, the second UV / visible light resistant layer 24a disposed or positioned in close proximity to a co-cured composite substrate 22a.

[0078] As shown in Figure 3A, each of the co-cured composite substrate 22a, the co-cured UV / visible light lightning-resistant protective layer 23a, and the second co-cured UV / visible light light-resistant layer 24a has a first side and a second side as shown and enumerated in Figure 2A. Both Figures 2A and 3A show co-cured composite assemblies (20a, 30a, e.g., assemblies configured to be co-cured together in a co-cure regime), with the difference between the co-cured composite assemblies 20a, 30a being in the placement of the co-cured UV / visible light lightning-resistant protective layer 23a. As shown in FIG. 2A, in co-cured composite assembly 20a, a co-cured UV / visible lightning resistant protective layer 23a is disposed proximate to co-cured composite substrate 22a, while as shown in FIG. 3A, in co-cured composite assembly 30a, a second co-cured UV / visible light resistant layer 24a is disposed proximate to co-cured composite substrate 22a.

[0079] FIG. 3B is an enlarged representative cross-sectional view of a co-cured UV / visible light resistant composite assembly 30b of a type usable as a structural assembly for an aircraft, including, for example, the exterior surface of the aircraft, according to an embodiment of the present disclosure, where the co-cured UV / visible light resistant composite assembly 30b includes a co-cured UV / visible light lightning resistant protective layer 23b and a second co-cured UV / visible light resistant layer 24b disposed or positioned in close proximity to the co-cured composite substrate 22a.

[0080] As shown in FIG. 3B, each of the co-cured composite substrate 22b, the co-cured UV / visible light lightning-resistant protective layer 23b, and the second co-cured UV / visible light light resistant layer 24b has a first side and a second side as shown and enumerated in FIG. 2B. Both FIG. 2B and FIG. 3B show a co-cured composite assembly (20b, 30b), and the difference between the co-cured composite assemblies 20b, 30b is the placement of the co-cured UV / visible light lightning-resistant protective layer 23b in the co-cured composite assembly. As shown in FIG. 2B, in the co-cured composite assembly 20b, the co-cured UV / visible light lightning-resistant protective layer 23b is placed in close proximity to the co-cured composite substrate 22b, while as shown in FIG. 3B, in the co-cured composite assembly 30b, it is the second co-cured UV / visible light light resistant layer 24b that is placed in close proximity to the co-cured composite substrate 22b.

[0081] After co-curing, both the co-cured UV / visible light lightning resistant protective layer and the second co-cured UV / visible light resistant layer can be configured to receive additional coating layers, which can include, for example, a definition primer layer, an assembly primer layer, etc., and the additional coating layers can be configured to receive topcoats, including, for example, a final topcoat. Figures 4A, 4B, 5A, 5B, 7, and 8 are enlarged representative cross-sectional views of co-cured composite assemblies according to embodiments of the present disclosure, illustrating how additional primer assembly coating layers and / or definition primer layers have been incorporated into the composite assemblies according to embodiments of the present disclosure.

[0082] According to aspects of the present disclosure, the co-cured composite assembly facilitates passage of electrical current (e.g., from a lightning strike, etc.) through the composite assembly and system, where the electrical current follows established conductive paths within a structure that is, for example, affected by a lightning strike or other EME. Correspondingly, aspects of the present disclosure contemplate orienting a co-cured UV / visible light resistant protective layer within the co-cured composite assembly at a location away from the co-cured composite substrate itself (which may be damaged, for example, from a lightning strike).

[0083] 4A and 4B are enlarged representative cross-sectional views of a co-cured UV / visible light resistant composite system according to an embodiment of the present disclosure, with a reduced amount of definition primer layer and no additional UV / visible light resistant paint layer that would otherwise be required, two of the many advantages resulting from the co-cured UV / visible light resistant composite assembly disclosed herein. In FIG. 4A, a co-cured UV / visible light lightning resistant protective layer according to an embodiment of the present disclosure is shown disposed or positioned in close proximity to a co-cured composite substrate in a composite assembly. In FIG. 4B, a second co-cured UV / visible light resistant layer according to an embodiment of the present disclosure is shown disposed or positioned in close proximity to a co-cured composite substrate in a composite assembly.

[0084] More specifically, FIG. 4A illustrates a composite system 40a including a layered system further including a co-cured composite assembly 20b (also shown in FIG. 2B ), where the co-cured composite assembly 20b includes a co-cured composite substrate 22b having a co-cured composite substrate first side 22b′ and a co-cured composite substrate second side 22b″. A co-cured UV / visible light lightning resistant protective layer 23b is disposed proximate to the co-cured composite assembly substrate 22b, where the co-cured UV / visible light lightning resistant protective layer 23b has a co-cured UV / visible light lightning resistant protective layer first side 23b′ and a co-cured UV / visible light lightning resistant protective layer second side 23b″. Additionally, a second co-cured UV / visible light resistant layer 24b having a first side 24b' and a second side 24b" of the second co-cured UV / visible light resistant layer is shown disposed proximate to the co-cured UV / visible light light resistant light protection layer 23b. As further shown in FIG. 4A, the co-cured UV / visible light light resistant light protection layer 23b is disposed between the co-cured composite substrate 22b and the second co-cured UV / visible light resistant layer 24b. FIG. 4A further illustrates the co-cured composite assembly 20b coated with a layer, which may be a finishing layer, including a fine primer layer 32 in contact with and covering the second co-cured UV / visible light resistant layer, an assembly primer layer 34 in contact with and covering the fine primer layer 32, and a topcoat layer 36 in contact with and covering the assembly primer layer 34.

[0085] FIG. 4B illustrates a composite system 40b that includes a layered system further including a co-cured composite assembly 30b (also shown in FIG. 3B), where the co-cured composite assembly 30b includes a co-cured composite substrate 22b (having a co-cured composite substrate first side 22b' and a co-cured composite substrate second side 22b"). A second co-cured UV / visible light resistant layer 24b is disposed proximate to the co-cured composite assembly substrate 22b, where the second co-cured UV / visible light resistant layer 24b has a second co-cured UV / visible light resistant layer first side 24b' and a second co-cured UV / visible light resistant layer second side 24b". Additionally, co-cured UV / visible light lightning resistant layer 23b (having co-cured UV / visible light lightning resistant layer first side 23b' and co-cured UV / visible light lightning resistant layer second side 23b") is shown disposed proximate to second co-cured UV / visible light light resistant layer 24b. As further shown in FIG. 4B, second co-cured UV / visible light light resistant layer 24b is disposed adjacent to co-cured composite substrate 22b and co-cured UV / visible light lightning resistant layer 23b. 4B further illustrates the co-cured composite assembly 20b coated with layers, which may be finish layers, including a definition primer layer 32 in contact with and covering the co-cured UV / visible lightning resistant protective layer 23b, an assembly primer layer 34 in contact with and covering the definition primer layer 32, and a topcoat layer 36 in contact with and covering the assembly primer layer 34.

[0086] A further aspect of the present disclosure contemplates a composite assembly that may not require a fine layer, further simplifying the overall composite structural material system as compared to currently used composite assemblies and systems, potentially reducing the overall thickness and processing complexity of the composite assemblies and systems disclosed herein. Figures 5A and 5B show a composite assembly similar to that shown in Figures 4A and 4B, but without the fine primer layer.

[0087] More specifically, FIG. 5A illustrates a composite system 50a including a layered system further including a co-cured composite assembly 20b (also shown in FIGS. 2B and 4A ), where the co-cured composite assembly 20b includes a co-cured composite substrate 22b having a co-cured composite substrate first side 22b′ and a co-cured composite substrate second side 22b″. A co-cured UV / visible light lightning resistant protective layer 23b is disposed proximate to the co-cured composite assembly substrate 22b, where the co-cured UV / visible light lightning resistant protective layer 23b has a co-cured UV / visible light lightning resistant protective layer first side 23b′ and a co-cured UV / visible light lightning resistant protective layer second side 23b″. Additionally, a second co-cured UV / visible light resistant layer 24b (having a second co-cured UV / visible light resistant layer first side 24b' and a second co-cured UV / visible light resistant second side 24b") is shown disposed in close proximity to the co-cured UV / visible light resistant lightning protection layer 23b.

[0088] As further shown in Figure 5A, a co-cured UV / visible light resistant lightning protection layer 23b is disposed between the co-cured composite substrate 22b and the second co-cured UV / visible light resistant layer 24b. Figure 5A further shows the co-cured composite assembly 20b coated with layers, which may be topcoat layers, including an assembly primer layer 34 in contact with and covering the second co-cured UV / visible light resistant layer 24b, and a topcoat layer 36 in contact with and covering the assembly primer layer 34.

[0089] FIG. 5B illustrates a composite system 50b that includes a layered system further including a co-cured composite assembly 30b (also shown in FIGS. 3B and 4B ), where the co-cured composite assembly 30b includes a co-cured composite substrate 22b (having a co-cured composite substrate first side 22b′ and a co-cured composite substrate second side 22b″). A second co-cured UV / visible light resistant layer 24b is disposed proximate to the co-cured composite assembly substrate 22b, where the second co-cured UV / visible light resistant layer 24b has a second co-cured UV / visible light resistant layer first side 24b′ and a second co-cured UV / visible light resistant layer second side 24b″. Additionally, a co-cured UV / visible light lightning resistant protective layer 23b (having a first side 23b′ of the co-cured UV / visible light lightning resistant protective layer and a second side 23b″ of the co-cured UV / visible light lightning resistant protective layer) is shown disposed proximate to a second co-cured UV / visible light light resistant layer 24b. As further shown in FIG. 5B, a second co-cured UV / visible light light resistant layer 24b is disposed between (and proximate to) the co-cured composite substrate 22b and the co-cured UV / visible light lightning resistant protective layer 23b. FIG. 5B further illustrates a co-cured composite assembly 20b coated with a layer, which may be a finishing layer, including an assembly primer layer 34 in contact with and covering the co-cured UV / visible light lightning resistant protective layer 23b, and a topcoat layer 36 in contact with and covering the assembly primer layer 34.

[0090] According to an embodiment of the present disclosure, two co-cured UV / visible light resistant layers together with a co-cured composite substrate (three layers together) comprise a co-cured composite assembly, as shown in Figures 2A and 3A. Similarly, according to an embodiment of the present disclosure, two co-cured UV / visible light resistant layers together with a co-cured composite substrate (three layers together) comprise a co-cured composite assembly, as shown in Figures 2B, 3B, 4A, 4B, 5A, and 5B. The inclusion of a UV / visible light lightning resistant protection layer impacts the conductive properties to the composite assembly, where the composite assembly according to an embodiment of the present disclosure has a conductivity of about 2 x 10 7 Siemens / meter to 6.4 x 10 7 With conductivities ranging up to Siemens / meter.

[0091] According to a further aspect of the present disclosure, the co-cured UV / visible light lightning resistant protective layer disclosed herein and the co-cured second co-cured UV / visible light resistant layer can be combined into a single layer (e.g., a single ply layer), and The co-cured UV / visible light lightning-resistant layer disclosed herein and the co-cured second co-cured UV / visible light light resistant layer can be combined into a single layer (e.g., a single ply layer). Figure 6A is an enlarged representative cross-sectional view of a co-cured UV / visible light light resistant composite assembly 60a of a type that can be used as a structural assembly for an aircraft, including, for example, an exterior surface of the aircraft, where the co-cured UV / visible light light resistant composite assembly 60a includes a co-cured UV / visible light light resistant material layer 25a that includes (and is combined with) a co-cured UV / visible light light resistant material and an additional co-cured UV / visible light light resistant material that can be different or the same as the co-cured material components in the co-cured UV / visible light light resistant lightning-resistant material. As shown in FIG. 6A, according to an embodiment of the disclosure, a co-curable UV / visible light resistant material layer 25a is disposed on or otherwise proximate to a co-curable composite substrate 22a. As shown in FIG. 6A, the co-curable composite substrate 22a has a co-curable composite substrate first side 22a' and a co-curable composite substrate second side 22a". The co-curable UV / visible light resistant material layer 25a (including the co-curable UV / visible light lightning protection material) has a co-curable UV / visible light resistant material layer first side 25a' and a co-curable UV / visible light resistant material layer second side 25a".

[0092] 6B is an enlarged representative cross-sectional view of a co-cured UV / visible light resistant composite assembly 60b of a type that can be used as a structural assembly for an aircraft, including, for example, an exterior surface of the aircraft, where the co-cured UV / visible light resistant composite assembly 60b includes a co-cured UV / visible light resistant material layer 25b that includes (and combines) a co-cured UV / visible light light resistant material and an additional UV / visible light resistant material that can be different or the same as the material components in the co-cured UV / visible light light resistant light protection layer. As shown in FIG. 6B, according to an embodiment of the present disclosure, the co-cured UV / visible light resistant material layer 25b is disposed on or otherwise in close proximity to the co-cured composite substrate 22b. As shown in FIG. 6B, co-cured composite substrate 22b has a co-cured composite substrate first side 22b' and a co-cured composite substrate second side 22b". Co-cured UV / visible light resistant material layer 25b (including the co-cured UV / visible light lightning protection material) has a co-cured UV / visible light resistant material layer first side 25b' and a co-cured UV / visible light resistant material layer second side 25b".

[0093] 7 is an enlarged representative cross-sectional view of a composite material system 70 according to an embodiment of the present disclosure. As shown in FIG. 7, composite material system 70 includes a layered system further including a co-cured composite material assembly 60b (also shown in FIG. 6B ), where co-cured composite material assembly 60b includes a co-cured composite substrate 22b having a co-cured composite substrate first side 22b′ and a co-cured composite substrate second side 22b″. A co-cured UV / visible light resistant material layer 25b (including a co-cured UV / visible light lightning protection material) is shown in FIG. 7 as a layered system including a co-cured composite substrate 22b having a co-cured composite substrate first side 22b′ and a co-cured composite substrate second side 22b″. 7 shows the co-cured composite assembly 60b having a thickness of 100 nm and a thickness of 100 nm and being co-cured in close proximity to the co-cured composite substrate 22b to form a co-cured composite assembly 60b. Figure 7 further shows the co-cured composite assembly 60b coated with layers, which may be finish layers, including a definition primer layer 32 in contact with and covering the co-cured UV / visible light resistant material layer 25b, an assembly primer layer 34 in contact with and covering the definition primer layer 32, and a topcoat layer 36 (which may be a final topcoat layer) in contact with and covering the assembly primer layer 34.

[0094] Embodiments of the present disclosure further contemplate a composite material assembly of the type shown in Figure 7 that does not include a definition primer layer. Correspondingly, Figure 8 is an enlarged representative cross-sectional view of a composite material system 80 according to an embodiment of the present disclosure. As shown in FIG. 8, composite material system 80 includes a layered system further including a co-cured composite material assembly 60b (also shown in FIG. 6B ), where co-cured composite material assembly 60b includes a co-cured composite material substrate 22b having a co-cured composite material substrate first side 22b′ and a co-cured composite material substrate second side 22b″. A co-cured UV / visible light resistant material layer 25b (including a co-cured UV / visible light lightning protection material) is shown in FIG. 8 having a co-cured UV / visible light resistant material layer first side 25b′ and a co-cured UV / visible light resistant material layer second side 25b″ and is co-cured in close proximity to co-cured composite material substrate 22b to form co-cured composite material assembly 60b. FIG. 8 further illustrates a co-cured composite assembly 60b coated with layers that may be finishing layers, including a primer layer 34 that contacts and covers the co-cured UV / visible light resistant material layer 25b, and a topcoat layer (which may be the final topcoat layer) 36 that contacts and covers the assembly primer layer 34.

[0095] According to aspects of the present disclosure, a combined co-curable UV / visible light resistant material layer 25a (shown in FIGS. 6B, 7, and 8) can be applied to the composite substrate as a single layer, which can be a single ply layer, and co-cured with the composite substrate at a temperature ranging from about 250° F. to about 370° F. to form a co-cured composite assembly 60b. Additionally, the inclusion of the combined co-curable UV / visible light material layer 25a (FIGS. 6B, 7, 8) impacts conductive properties to the composite system 70, 80, where the composite assembly, according to aspects of the present disclosure, can have a conductivity of about 2×10 7 Siemens / meter to 6.4 x 10 7 With conductivities ranging up to Siemens / meter.

[0096] Aspects of the present disclosure eliminate or otherwise eliminate fine primer layers from the co-cured UV / visible light resistant composite assemblies and systems disclosed herein, and / or significantly reduce the amount and thickness of the fine primer layers. That is, according to aspects of the present disclosure, the average thickness of the fine primer layers is significantly reduced from the amount and layer thickness of fine primer previously required for known composite assemblies. Such reduction and / or elimination of fine primer can significantly reduce the complexity of composite preparation due to the scale of large structural assemblies, including, for example, aircraft, resulting in significant weight savings, cost savings, reduced processing time, reduced rework time, reduced manpower / labor per hour, and reduced material required.

[0097] Co-curing and / or co-cured composite structures, assemblies, and systems according to aspects of the present disclosure can be used in forming exterior surfaces of large structural assemblies, including, for example, large structural surfaces where lightning strike protection (LSP) may be desirable or required by industry regulations, etc. For example, according to aspects of the present disclosure, the co-curing and co-cured composite assemblies disclosed herein can be used as structural materials for, for example, aircraft wing assemblies, including exterior surfaces of wing assemblies, fuselage assemblies, aircraft fuel tank assemblies, nacelles, aircraft electronics shielding structures to provide lightning protection to selected aircraft assemblies and to aircraft including the selected aircraft assemblies, etc.

[0098] The co-curable composite substrate disclosed herein can be a co-curable carbon fiber reinforced polymer composite substrate, which can further be a co-curable epoxy resin based composite substrate co-cured with a UV / visible lightning resistant protective layer to form co-cured composite assemblies and systems.

[0099] According to further aspects of the present disclosure, the co-cured UV / visible light resistant composite assemblies and systems disclosed herein do not require the inclusion of additional UV / visible light resistant materials in the UV / visible light resistant composite assembly in any layer other than the second UV / visible light resistant layer and the UV / visible light light resistant lightning protection (LSP) layer, which in combination or individually, have UV / visible light transmittance values ​​ranging from about 0% to about 20% UV / visible light transmission for UV / visible light wavelengths ranging from about 200 nm to about 800 nm when the co-cured UV / visible light resistant lightning protection layer and / or the second UV / visible light resistant layer have an average thickness ranging from about 2 mils to about 6 mils.

[0100] The co-cured UV / visible light resistant composite assemblies disclosed herein do not include a UV / visible light resistant material, for example in the form of a UV / visible light resistant primer layer or a UV / visible light resistant paint layer. In other words, the second UV / visible light resistant layer and the UV / visible light light resistant lightning protection (LSP) layer are only involved in affecting the resistance to UV / visible light affecting the UV / visible light resistant composite assemblies and systems (e.g., inhibiting UV / visible light radiation from passing through the second UV / visible light resistant layer and the UV / visible light light resistant lightning protection (LSP) layer to the composite substrate).

[0101] Figures 9A, 9B, 10A, 10B, 11A, 11B, 12A, 12B, 13, and 14 are flow charts illustrating a method of making a co-cured UV / visible light resistant composite assembly disclosed herein including a co-cured UV / visible light lightning resistant protective layer disclosed herein, and / or a co-cured UV / visible light resistant composite assembly disclosed herein including a co-cured UV / visible light lightning resistant protective layer disclosed herein. Further aspects of the present disclosure contemplate structures comprising at least one of the co-curable composites, co-cured composites, assemblies comprising co-cured composites, subassemblies comprising co-cured composites, and assemblies and / or subassemblies comprising the co-cured UV / visible light resistant composites made according to the methods described herein, including, 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.

[0102] 9A illustrates a method of making a co-curing composite assembly, where the method 900a includes disposing and / or applying a co-curing UV / visible light lightning-resistant protective layer on a co-curing composite substrate layer, which may be a co-curing epoxy resin-based composite and may be a carbon fiber reinforced polymer (902). The method 900a further includes disposing and / or applying a second co-curing UV / visible light lightning-resistant layer on the co-curing UV / visible light lightning-resistant protective layer to form a co-curing composite substrate assembly (equivalently referred to as a co-curing composite system) (904). The co-curing composite substrate layer may be a co-curing epoxy resin-based composite substrate and may be a carbon fiber reinforced polymer.

[0103] The co-cured composite assembly including the UV / visible light lightning resistant protective layer and / or the second co-cured UV / visible light light resistant layer may be at least of the type shown and described in Figure 2A, where the co-cured UV / visible light lightning resistant protective layer is in direct contact with the co-cured composite substrate and the co-cured UV / visible light lightning resistant protective layer is disposed (e.g., "sandwiched") between the co-cured composite substrate and the co-cured lightning resistant protective layer. The co-cured composite may be at least of the type shown and described in Figure 2A herein.

[0104] 9B illustrates a method of making a co-curing composite assembly, method 900b, including disposing and / or applying a second co-curing UV / visible light resistant layer on the co-curing composite substrate 906, and then disposing and / or applying a co-curing UV / visible light lightning protection layer on the second co-curing UV / visible light resistant layer to form a co-curing composite substrate assembly (also equivalently referred to as a co-curing composite system) 908. The co-curing composite substrate layer can be a co-curing epoxy resin based composite substrate and can further be a carbon fiber reinforced polymer. The co-cured composite assembly including the UV / visible light lightning resistant protective layer and / or the second co-cured UV / visible light lightning resistant layer may be at least of the type shown and described in Figure 2B, where the co-cured UV / visible light lightning resistant protective layer is not in direct contact with the co-cured composite substrate, and the second co-cured UV / visible light lightning resistant protective layer is disposed (e.g., "sandwiched") between the co-cured composite substrate and the co-cured UV / visible light lightning resistant protective layer. The co-cured composite may be at least of the type shown and described in Figure 3A herein.

[0105] According to an aspect of the disclosure described in the methods 900a and 900b shown in Figures 9A and 9B, respectively, one or more of the second co-cured UV / visible light resistant layer and the co-cured UV / visible light light resistant lightning protection layer may each be a single ply. According to a further aspect of the disclosure, one or more of the second co-cured UV / visible light resistant layer and the co-cured UV / visible light light resistant lightning protection layer may each be a plurality of plies, and one or more of the plurality of plies and / or the single ply includes at least one of glass fiber, carbon fiber, polyester fiber, aramid fiber, quartz, and combinations thereof.

[0106] FIG. 10A illustrates a method of making the co-curable composite assembly shown in FIG. 9A according to an embodiment of the present disclosure, where the method 1000a further includes co-curing the co-curable composite assembly to form a co-cured UV / visible light resistant composite assembly (909) of at least the type shown and described in FIG. 2B.

[0107] FIG. 10B illustrates a method of making the co-curable composite assembly shown in FIG. 9B according to an embodiment of the present disclosure, where the method 1000b further includes co-curing the co-curable composite assembly to form a co-cured UV / visible light resistant composite assembly (909) of at least the type shown and described in FIG. 3B.

[0108] FIG. 11A illustrates a method of making the co-cured composite assembly shown in FIG. 10A, where method 1100a further includes applying a fine primer layer to the co-cured UV / visible light resistant composite assembly (1102), applying an assembly primer layer to the fine primer layer (1104), and applying a topcoat layer to the assembly primer layer (1106).

[0109] FIG. 11B illustrates a method of making the co-cured composite assembly shown in FIG. 10B, where method 1100b further includes applying a definition primer layer to the co-cured UV / visible light resistant composite assembly (1102), applying an assembly primer layer to the definition primer layer (1104), and applying a topcoat layer to the assembly primer layer (1106).

[0110] FIG. 12A illustrates a method 1200a of making the co-cured composite assembly shown in FIG. 10A, which further includes applying an assembly primer layer to the co-cured UV / visible light resistant composite assembly (1105) and applying a topcoat layer to the assembly primer layer (1106).

[0111] FIG. 12B illustrates a method 1200b of making the co-cured composite assembly shown in FIG. 10B, further comprising applying an assembly primer layer to the co-cured UV / visible light resistant composite assembly (1105) and applying a topcoat layer to the assembly primer layer (1106).

[0112] The "co-curing" step 909 described in methods 1000a, 100b, 1100a, 1100b, 1200a, 1200b shown in Figures 10A, 10B, 11A, 11B, 12A, 12B, respectively, herein can be carried out at temperatures ranging from about 250°F to about 370°F within a co-curing regime (including observed ramp-up, cool-down, and dwell times, if necessary, at a particular temperature within the aforementioned temperature range) determined by the materials selected for the co-curing composite substrate and the co-curing UV / visible light light-resistant lightning protection layer and the second co-curing UV / visible light light-resistant layer.

[0113] As used herein, the co-cured UV / visible light lightning resistant protective layer and the second co-cured UV / visible light light resistant layer can be provided as separate layers (having a single ply or multiple plies of each of the separate material "layers") to form the described co-cured UV / visible light resistant composite assemblies, and further aspects of the present disclosure (including those described with respect to Figures 6A, 6B, 7, and 8 herein) contemplate combining the co-cured UV / visible light lightning resistant protective material and the second co-cured UV / visible light resistant material into a single layer, which may include a single ply or multiple plies of combined materials, and then applying the combined material layers to a co-cured composite substrate to form the described co-cured UV / visible light resistant composite assemblies.

[0114] 13 illustrates a method 1300 of making a co-cured UV / visible light resistant composite assembly, the method 1300 including applying 903 a co-curing single layer of material (a single material combining a co-curing UV / visible light resistant lightning protection material and a second co-curing UV / visible light resistant material) to a co-curing composite substrate (which may be a co-curing epoxy resin composite substrate). The method 1300 further includes co-curing 909 the co-curing composite substrate to form a co-cured UV / visible light resistant composite substrate of the type shown and described in at least FIGS. 6A, 6B, 7, and 8 according to an embodiment of the present disclosure. The method 1300 further includes applying a definition primer layer to the co-cured UV / visible light resistant composite assembly (1102), applying an assembly primer layer to the definition primer layer (1104), and applying a topcoat layer to the assembly primer layer (1106).

[0115] FIG. 14 illustrates a method 1400 of making a co-cured UV / visible light resistant composite assembly, the method 1400 including applying (903) a co-curing single layer of material (a single material combining a co-curing UV / visible light resistant lightning protection material and a second co-curing UV / visible light resistant material) to a co-curing composite substrate (which may be a co-curing epoxy resin composite substrate). The method 1400 further includes co-curing (909) the co-curing composite substrate to form a co-cured UV / visible light resistant composite substrate of the type shown and described in at least FIGS. 6A, 6B, 7, and 8 according to an embodiment of the present disclosure. The method 1400 further includes applying (1105) an assembly primer layer to the co-cured UV / visible light resistant composite substrate and applying (1106) a topcoat layer to the assembly primer layer.

[0116] Furthermore, the present disclosure includes embodiments according to the following clauses:

[0117] Clause 1. A co-curable composite assembly (20a), comprising: a co-curable composite substrate (22a); a co-curing ultraviolet (UV) / visible light lightning protection layer (23a); Including, A co-curable composite assembly (20a) in which the co-curable composite substrate is co-curable with the co-curable UV / visible lightning resistant protective layer at a temperature ranging from about 250°F to about 370°F.

[0118] Clause 2. The co-curable composite assembly of clause 1, wherein the co-curable composite substrate comprises a carbon fiber reinforced polymer.

[0119] Clause 3. The co-curable composite assembly of clause 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, glass fiber, polyester fiber, and combinations thereof.

[0120] Clause 4. The co-curable composite assembly of clause 1, wherein the co-curable composite substrate comprises a plurality of carbon fiber reinforced polymer prepregs.

[0121] Clause 5. A co-curable composite assembly as described in clause 1, wherein the co-curable composite substrate is in direct contact with and immediately adjacent to the co-curable UV / visible light lightning resistant protective layer.

[0122] Clause 6. The co-curable composite assembly of clause 1, further comprising a second co-cured UV / visible light resistant layer (24a) as a separate layer, wherein both the second co-cured UV / visible light resistant layer and the co-cured UV / visible light light resistant lightning protection layer are co-curable with the co-curable composite substrate at a temperature in the range of from about 250°F to about 370°F.

[0123] Clause 7. The co-curable composite assembly (30a) of clause 6, further configured such that a second co-curable UV / visible light resistant layer is located immediately adjacent to the co-curable composite substrate, the second co-curable UV / visible light resistant layer being located between the co-curable composite substrate and the co-curable UV / visible light resistant lightning protection layer.

[0124] Clause 8. The co-curable composite assembly of clause 6, wherein the second co-curable UV / visible light resistant layer is a separate layer within the co-curable composite assembly.

[0125] Clause 9. The co-cured composite assembly of clause 6, wherein at least one of the co-cured UV / visible light lightning resistant protective layer and the second co-cured UV / visible light resistant layer comprises at least one of glass fiber, carbon fiber, polyester fiber, aramid fiber, quartz, and combinations thereof.

[0126] Clause 10. The co-cured composite assembly of clause 6, wherein at least one of the co-cured UV / visible light lightning protection layer and the second co-cured UV / visible light light resistant layer is a co-cured UV / visible light light fiberglass containing layer.

[0127] Clause 11. A co-cured composite assembly (20b)(30b)(40a)(40b)(50a)(50b)(60b)(70)(80), comprising: a co-cured composite substrate (22b); a co-cured ultraviolet (UV) / visible light lightning protection layer (23b); Including, Co-cured UV / visible light lightning resistant protective layer when the co-cured UV / visible lightning resistant protective layer has an average thickness in the range of about 2 mils to about 6 mils, the UV / visible light transmittance values ​​are in the range of about 0% to about 20% UV / visible light transmission for wavelengths in the UV / visible light range of about 200 nm to about 800 nm; Co-cured UV / visible light lightning resistant protective layer is 2×10 7 Siemens / meter to 6.4 x 10 7 A co-cured composite assembly (20b)(30b)(40a)(40b)(50a)(50b)(60b)(70)(80) having a conductivity in the Siemens / meter range.

[0128] Clause 12. The co-cured composite assembly of clause 11, wherein the co-cured composite substrate is co-cured with the co-cured UV / visible lightning resistant protective layer at a temperature ranging from about 250°F to about 370°F.

[0129] Clause 13. The co-cured composite assembly of clause 11, wherein the co-cured composite substrate comprises a carbon fiber reinforced polymer.

[0130] Clause 14. The co-cured composite assembly of clause 11, wherein the co-cured composite substrate comprises an epoxy resin-based compound, and the co-cured composite substrate further comprises at least one of carbon fiber, boron fiber, aramid fiber, glass fiber, polyester fiber, and combinations thereof.

[0131] Clause 15. The co-cured composite assembly (20b)(30b)(40a)(50a)(60b)(70)(80) of clause 11, wherein the co-cured composite substrate is in direct contact with and immediately adjacent to the co-cured UV / visible light lightning resistant protective layer.

[0132] Clause 16. The co-cured composite assembly (40a)(40b)(50a)(50b)(70)(80) of clause 11, further comprising an assembly primer layer (34), and the co-cured composite assembly further comprises a topcoat layer (36) disposed on the assembly primer layer.

[0133] Clause 17. The co-cured composite assembly (40a)(40b)(70) of clause 16, further comprising a definition primer layer (32) disposed between the co-cured UV / visible light lightning resistant protective layer and the assembly primer layer.

[0134] Clause 18. The co-cured composite assembly of clause 11, further comprising a second co-cured UV / visible light resistant layer (24b), wherein both the second co-cured UV / visible light resistant layer and the co-cured UV / visible light light resistant lightning protection layer are co-cured with the co-cured composite substrate.

[0135] Clause 19. The co-cured composite assembly (30b)(40b)(50b) of clause 18, wherein a second co-cured UV / visible light resistant layer is positioned between the co-cured composite substrate and the co-cured UV / visible light resistant lightning protection layer.

[0136] Clause 20. The co-cured composite assembly (40b)(50b) of clause 19, further comprising an assembly primer layer disposed on the co-cured UV / visible light lightning resistant protective layer, the co-cured composite assembly further comprising a topcoat layer disposed on the assembly primer layer.

[0137] Clause 21. The co-cured composite assembly (40b) of clause 20, further comprising a definition primer layer disposed between the assembly primer layer and the co-cured UV / visible light lightning resistant protective layer.

[0138] Clause 22. The co-cured composite assembly (20b)(30b)(40a)(50a) of clause 18, wherein the co-cured UV / visible light resistant lightning protection layer is located between the co-cured composite substrate and the second co-cured UV / visible light resistant layer.

[0139] Clause 23. The co-cured composite assembly (50a) of clause 18, further comprising an assembly primer layer disposed on the second co-cured UV / visible light resistant layer, the co-cured composite assembly further comprising a topcoat layer disposed on the assembly primer layer.

[0140] Clause 24. The co-cured composite assembly (40a) of clause 20, further comprising a definition primer layer disposed on the second co-cured UV / visible light resistant layer.

[0141] Clause 25. The co-cured composite assembly of clause 18, wherein at least one of the co-cured UV / visible light lightning resistant protective layer and the second co-cured UV / visible light resistant layer comprises at least one of glass fiber, carbon fiber, polyester fiber, aramid fiber, quartz, and combinations thereof.

[0142] Clause 26. The co-cured composite assembly of clause 18, wherein at least one of the co-cured UV / visible light lightning protection layer and the second co-cured UV / visible light light resistant layer comprises a co-cured UV / visible light glass fiber-containing layer.

[0143] Clause 27. A vehicle comprising the co-cured composite assembly of clause 11, wherein 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 land vehicle, an unmanned land vehicle, a manned surface vehicle, an unmanned surface vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

[0144] Clause 28. A vehicle comprising the co-cured composite assembly of clause 15, wherein 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 land vehicle, an unmanned land vehicle, a manned surface vehicle, an unmanned surface vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

[0145] Clause 29. A vehicle comprising the co-cured composite assembly of clause 19, wherein 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 land vehicle, an unmanned land vehicle, a manned surface vehicle, an unmanned surface vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

[0146] Clause 30. A method (900a) for making a thermosetting composite assembly, comprising: Providing a co-curable composite substrate; disposing a co-cured ultraviolet (UV) / visible light lightning protection layer on the co-cured composite substrate to form a co-cured composite lightning protection assembly; Including, The method (900a), wherein the co-curable composite substrate may be co-cured with the co-curable UV / visible lightning resistant protective layer at a temperature ranging from about 250°F to about 370°F.

[0147] Article 31. 31. The method (900a) of clause 30, further comprising disposing a co-cured UV / visible lightning resistant protective layer proximate to the co-cured composite substrate.

[0148] Clause 32. The method (900a)(900b) of clause 30, further comprising providing a second co-cured UV / visible light resistant layer to the co-cured composite assembly.

[0149] Article 33. 33. The method of claim 32, further comprising disposing a second co-cured UV / visible light resistant layer between the co-cured composite substrate and the co-cured UV / visible light lightning resistant protective layer (900b).

[0150] Article 34. 33. The method (900a) of claim 32, further comprising disposing a co-cured UV / visible light resistant lightning protection layer between the co-cured composite substrate and the second co-cured UV / visible light resistant layer in a co-cured composite lightning protection assembly.

[0151] Clause 35. A method (1000a)(1000b) for making a co-cured composite assembly, comprising: Providing a co-curable composite substrate; disposing a co-cured ultraviolet (UV) / visible light lightning protection layer on the co-cured composite substrate to form a co-cured composite lightning protection assembly; co-curing the co-curable composite lightning protection assembly at a temperature in the range of about 250° F. to about 370° F. to form a co-cured composite assembly; Including, Co-cured UV / visible light lightning resistant protective layer is 2×10 7 Siemens / meter to 6.4 x 10 7 The method (1000a)(1000b), having a conductivity in the range of Siemens / meter.

[0152] Article 36. 36. The method (1000a) of clause 35, further comprising disposing a co-cured UV / visible lightning resistant protective layer proximate to the co-cured composite substrate.

[0153] Clause 37. The method (1000b) of clause 35, further comprising providing the co-cured composite lightning strike assembly with a second co-cured UV / visible light resistant layer prior to co-curing.

[0154] Article 38. 38. The method of claim 37, further comprising disposing a second co-cured UV / visible light resistant layer between the co-cured composite substrate and the co-cured UV / visible light lightning resistant protective layer (1000b).

[0155] Article 39. 38. The method (1000a) of claim 37, further comprising disposing a co-cured UV / visible light resistant lightning protection layer between the co-cured composite substrate and the second co-cured UV / visible light resistant layer in a co-cured composite lightning protection assembly.

[0156] The present aspects can, of course, be practiced otherwise than as specifically described herein without departing from the essential characteristics of the disclosure. The present aspects 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 appended claims are intended to be embraced therein.

Claims

1. A co-curable composite material assembly (20a), A co-curable composite material substrate (22a), Co-curing ultraviolet (UV) / visible light thunderproof protective layer (23a), Includes, A co-curable composite material assembly (20a) wherein the co-curable composite material substrate can co-cure with the co-curable UV / visible light-resistant protective layer at temperatures ranging from approximately 121°C (250°F) to approximately 188°C (370°F).

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

3. The co-curable composite material assembly according to claim 1, wherein the co-curable composite material substrate comprises an epoxy resin-based 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.

4. 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.

5. The co-curable composite material assembly according to claim 1, wherein the co-curable composite material substrate is in direct contact with and located very close to the co-curable UV / visible light-resistant protective layer.

6. The co-curable composite material assembly according to claim 1, further comprising as a separate layer a second co-curable UV / visible light-resistant layer (24a), wherein both the second co-curable UV / visible light-resistant layer and the co-curable UV / visible light-resistant protective layer can co-cure with the co-curable composite material substrate at temperatures ranging from approximately 121°C (250°F) to approximately 188°C (370°F).

7. The co-curable composite material assembly (30a) according to claim 6, wherein the second co-curable UV / visible light resistant layer is located in close proximity to the co-curable composite material substrate, and the second co-curable UV / visible light resistant layer is further configured to be located between the co-curable composite material substrate and the co-curable UV / visible light resistant protective layer.

8. The co-curable composite material assembly according to claim 6, wherein the second co-curable UV / visible light resistant layer is a separate layer within the co-curable composite material assembly.

9. The co-curable composite material assembly according to claim 6, wherein at least one of the co-curable UV / visible light resistant protective layer and the second co-curable UV / visible light resistant layer comprises at least one of glass fibers, carbon fibers, polyester fibers, aramid fibers, quartz, and combinations thereof.

10. The co-curable composite material assembly according to claim 6, wherein at least one of the co-curable UV / visible light-resistant protective layer and the second co-curable UV / visible light-resistant layer is a co-curable UV / visible light-resistant glass fiber-containing layer.

11. Co-cured composite material assemblies (20b)(30b)(40a)(40b)(50a)(50b)(60b)(70)(80), Co-cured composite material substrate (22b), Co-cured ultraviolet (UV) / visible light lightning protection layer (23b), Includes, When the co-cured UV / visible light-resistant protective layer has an average thickness ranging from approximately 2 mils to approximately 6 mils, the UV / visible light transmittance value is approximately 0% to approximately 20% for UV / visible light wavelengths ranging from approximately 200 nm to approximately 800 nm. The aforementioned co-cured UV / visible light resistant protective layer is 2 × 10 ７ Siemens / meters, 6.4 x 10 ７ Co-cured composite material assemblies (20b)(30b)(40a)(40b)(50a)(50b)(60b)(70)(80) having conductivity in the range of Siemens / meter.

12. The co-cured composite material assembly according to claim 11, wherein the co-cured composite material substrate is co-cured with the co-cured UV / visible light-resistant protective layer at a temperature in the range of about 121°C (250°F) to about 188°C (370°F).

13. The co-cured composite material assembly according to claim 11, wherein the co-cured composite material substrate comprises a carbon fiber reinforced polymer.

14. The co-cured composite material assembly according to claim 11, wherein the co-cured composite material substrate comprises an epoxy resin-based compound, and the co-cured composite material substrate further comprises at least one of carbon fibers, boron fibers, aramid fibers, glass fibers, polyester fibers, and combinations thereof.

15. The co-cured composite material assembly (20b)(30b)(40a)(50a)(60b)(70)(80) according to claim 11, wherein the co-cured composite material substrate is in direct contact with and located in close proximity to the co-cured UV / visible light resistant protective layer.

16. The co-cured composite material assembly (40a)(40b)(50a)(50b)(70)(80) according to claim 11, further comprising an assembly primer layer (34), wherein the co-cured composite material assembly further comprises a top coat layer (36) disposed on the assembly primer layer.

17. The co-cured composite material assembly (40a) (40b) (70) according to claim 16, further comprising a fine primer layer (32) disposed between the co-cured UV / visible light resistant protective layer and the assembly primer layer.

18. The co-cured composite material assembly according to claim 11, further comprising a second co-cured UV / visible light-resistant layer (24b), wherein both the second co-cured UV / visible light-resistant layer and the co-cured UV / visible light-resistant protective layer are co-cured with the co-cured composite material substrate.

19. The co-cured composite material assembly (30b) (40b) (50b) according to claim 18, wherein the second co-cured UV / visible light resistant layer is located between the co-cured composite material substrate and the co-cured UV / visible light resistant protective layer.

20. The co-cured composite material assembly (40b) (50b) according to claim 19, further comprising an assembly primer layer disposed on the co-cured UV / visible light resistant protective layer, wherein the co-cured composite material assembly further comprises a top coat layer disposed on the assembly primer layer.

21. The co-cured composite material assembly (40b) according to claim 20, further comprising a fine primer layer disposed between the assembly primer layer and the co-cured UV / visible light resistant protective layer.

22. The co-cured composite material assembly (20b)(30b)(40a)(50a) according to claim 18, wherein the co-cured UV / visible light resistant protective layer is located between the co-cured composite material substrate and the second co-cured UV / visible light resistant layer.

23. The co-cured composite material assembly (50a) according to claim 18, further comprising an assembly primer layer disposed on the second co-cured UV / visible light resistant layer, wherein the co-cured composite material assembly further comprises a top coat layer disposed on the assembly primer layer.

24. The co-cured composite material assembly (40a) according to claim 20, further comprising a fine primer layer disposed on the second co-cured UV / visible light resistant layer.

25. The co-cured composite material assembly according to claim 18, wherein at least one of the co-cured UV / visible light resistant protective layer and the second co-cured UV / visible light resistant layer comprises at least one of glass fibers, carbon fibers, polyester fibers, aramid fibers, quartz, and combinations thereof.

26. The co-cured composite material assembly according to claim 18, wherein at least one of the co-cured UV / visible light-resistant protective layer and the second co-cured UV / visible light-resistant layer comprises a co-cured UV / visible light-resistant glass fiber-containing layer.

27. A vehicle comprising a co-cured composite material assembly according to claim 11, wherein the vehicle is selected from the group consisting of a manned aircraft, an unmanned aircraft, a manned spacecraft, an unmanned spacecraft, a manned rotary-wing aircraft, an unmanned rotary-wing aircraft, a manned land vehicle, an unmanned land vehicle, a manned water vehicle, an unmanned water vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

28. A vehicle comprising a co-curing composite material assembly according to claim 15, wherein the vehicle is selected from the group consisting of a manned aircraft, an unmanned aircraft, a manned spacecraft, an unmanned spacecraft, a manned rotary-wing aircraft, an unmanned rotary-wing aircraft, a manned land vehicle, an unmanned land vehicle, a manned water vehicle, an unmanned water vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

29. A vehicle comprising a co-curing composite material assembly according to claim 19, wherein the vehicle is selected from the group consisting of a manned aircraft, an unmanned aircraft, a manned spacecraft, an unmanned spacecraft, a manned rotary-wing aircraft, an unmanned rotary-wing aircraft, a manned land vehicle, an unmanned land vehicle, a manned water vehicle, an unmanned water vehicle, a manned underwater vehicle, an unmanned underwater vehicle, a satellite, and combinations thereof.

30. A method (900a) for producing a co-curable composite material assembly, By providing a co-curable composite material substrate, A co-curable composite material lightning protection assembly is formed by placing a co-curable ultraviolet (UV) / visible lightning protection layer on the aforementioned co-curable composite material substrate. Includes, A method (900a) in which the co-curable composite material substrate can co-cur with the co-curable UV / visible light-resistant protective layer at a temperature in the range of about 250°F to about 370°F.

31. The method according to claim 30 (900a), further comprising locating the co-curable UV / visible light thunderproof protective layer in close proximity to the co-curable composite material substrate.

32. The method according to claim 30 (900a) (900b), further comprising providing a second co-curable UV / visible light resistant layer to the co-curable composite material assembly.

33. The method according to claim 32 (900b), further comprising arranging the second co-curable UV / visible light-resistant layer between the co-curable composite material substrate and the co-curable UV / visible light-resistant light-resistant protective layer.

34. The method according to claim 32 (900a), further comprising arranging the co-curable UV / visible light-resistant lightning protection layer between the co-curable composite material substrate and the second co-curable UV / visible light-resistant layer in the co-curable composite material lightning protection assembly.

35. A method (1000a) (1000b) for producing a co-cured composite material assembly, By providing a co-curable composite material substrate, A co-curable composite material lightning protection assembly is formed by placing a co-curable ultraviolet (UV) / visible lightning protection layer on the aforementioned co-curable composite material substrate. The co-curable composite material lightning protection assembly is co-cured at a temperature in the range of approximately 121°C (250°F) to approximately 188°C (370°F) to form a co-cured composite material assembly. Includes, The co-cured UV / visible light resistant protective layer is 2 × 10 ７ Siemens / meters, 6.4 x 10 ７ Having conductivity in the range of Siemens / meter, Method (1000a) (1000b).

36. The method according to claim 35 (1000a), further comprising placing the co-curable UV / visible light resistant protective layer in close proximity to the co-curable composite material substrate.

37. The method according to claim 35 (1000a) (1000b), further comprising providing a second co-curable UV / visible light-resistant layer to the co-curable composite material lightning protection assembly before co-curing.

38. The method according to claim 37 (1000b), further comprising arranging the second co-curable UV / visible light-resistant layer between the co-curable composite material substrate and the co-curable UV / visible light-resistant light-proof protective layer.

39. The method according to claim 37 (1000a), further comprising arranging the co-curable UV / visible light-resistant lightning protection layer between the co-curable composite material substrate and the second co-curable UV / visible light-resistant layer in the co-curable composite material lightning protection assembly.

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