Method for manufacturing composite structures having carbon-reinforced composites and glass-reinforced composites

JP2026102465APending Publication Date: 2026-06-23THE BOEING CO
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Patent Information

Authority / Receiving Office
JP · JP
Patent Type
Applications
Current Assignee / Owner
THE BOEING CO
Filing Date
2025-11-21
Publication Date
2026-06-23

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Abstract

This disclosure relates to glass fiber composite shim composite structures, and more particularly to methods for manufacturing composite structures having carbon-reinforced composite materials and glass-reinforced composite materials. [Solution] A method for manufacturing a composite structure having carbon-reinforced composite components and glass-reinforced composite components, comprising contacting a glass-reinforced composite material with a carbon-reinforced composite material to produce a composite layup, wherein the glass-reinforced composite material comprises a glass-reinforcement material and a polymer matrix material, the glass-reinforcement material having a silica content of at least 60 percent, and the method further comprises co-curing the composite layup.
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Claims

1. A method (1000) for manufacturing a composite structure (2000) including carbon-reinforced composite components (2010) and glass-reinforced composite components (2020), The method involves bringing a glass-reinforced composite material (2200) into contact with a carbon-reinforced composite material (2100) (1200) to produce a composite material layup (2300), wherein the glass-reinforced composite material (2200) comprises a glass-reinforced material (2220) and a polymer matrix material (2210), and the glass-reinforced material (2220) has a low coefficient of thermal expansion, and the method involves producing a composite material layup (2300), and A method (1000) comprising co-curing (1300) the composite material layup (2300).

2. The method according to claim 1 (1000), wherein the composite material layup (2300) includes at least one of S-2 glass and Astroquarts.

3. The method according to claim 1 (1000), wherein the glass reinforcing material (2220) includes glass fibers.

4. The glass reinforcing material (2220) has a high silica content, according to the method of claim 1 (1000).

5. The method according to claim 1 (1000), wherein the glass reinforcing material (2220) has a silica content of at least 60 weight percent.

6. The method according to claim 1 (1000), wherein the glass reinforcing material (2220) has a silica content of at least 80 weight percent.

7. The method according to claim 1 (1000), wherein the glass reinforcing material (2220) has a silica content of at least 99 weight percent.

8. The method according to claim 1 (1000), wherein the glass reinforcing material (2220) has a thermal expansion coefficient between approximately 0.1 μm / m°C and approximately 4 μm / m°C.

9. The method according to claim 1 (1000), wherein the glass reinforcing material (2220) has a thermal expansion coefficient of at least 0.5 μm / m°C.

10. The method according to claim 1 (1000), wherein the glass reinforcing material (2220) has a maximum thermal expansion coefficient of 4 μm / m°C.

11. The method according to claim 1 (1000), wherein the polymer matrix material (2210) of the glass-reinforced composite material (2200) includes a thermosetting resin.

12. The method according to claim 11 (1000), wherein the thermosetting resin includes epoxy.

13. The method according to claim 11 (1000), wherein the thermosetting resin comprises at least one of epoxy, bismaleimide, cyanate ester, and polyimide.

14. The method according to claim 1 (1000), wherein the carbon-reinforced composite material (2100) comprises a carbon-reinforced material (2120) and a polymer matrix material (2110).

15. The carbon-reinforced material (2120) comprises carbon fibers, according to the method of claim 14 (1000).

16. The carbon-reinforced material (2120) has a maximum thermal expansion coefficient of 2 μm / m°C, according to the method of claim 14 (1000).

17. The carbon-reinforced material (2120) has a maximum thermal expansion coefficient of 1.5 μm / m°C, according to the method of claim 14 (1000).

18. The carbon-reinforced material (2120) has a maximum thermal expansion coefficient of 1 μm / m°C, according to the method of claim 14 (1000).

19. The method according to claim 14 (1000), wherein the polymer matrix material (2110) of the carbon-reinforced composite material (2100) includes a thermosetting resin.

20. The method according to claim 19 (1000), wherein the thermosetting resin includes epoxy.

21. The method according to claim 19 (1000), wherein the thermosetting resin comprises at least one of epoxy, bismaleimide, cyanate ester, and polyimide.

22. The method according to claim 14 (1000), wherein the polymer matrix material (2110) of the carbon-reinforced composite material (2100) and the polymer matrix material (2210) of the glass-reinforced composite material (2200) are compositionally the same.

23. The method according to claim 14 (1000), wherein the polymer matrix material (2110) of the carbon-reinforced composite material (2100) and the polymer matrix material (2210) of the glass-reinforced composite material (2200) are compositionally different.

24. The method according to claim 14 (1000), wherein the thermal expansion coefficient of the glass-reinforced material (2220) is between approximately 30 percent and approximately 200 percent of the thermal expansion coefficient of the carbon-reinforced material (2120).

25. The method according to claim 14 (1000), wherein the thermal expansion coefficient of the glass-reinforced material (2220) is between approximately 35 percent and approximately 150 percent of the thermal expansion coefficient of the carbon-reinforced material (2120).

26. The glass-reinforced composite material (2200) has an average cross-sectional thickness (T) between approximately 0.02 inches and approximately 0.1 inches. 1 The method according to claim 1 (1000), having ).

27. The carbon-reinforced composite material (2100) has the average cross-sectional thickness (T) of the glass-reinforced composite material (2200). 1 ) is at least 10 times greater than the average cross-sectional thickness (T 2 The method according to claim 1 (1000), having ).

28. The method according to claim 1 (1000), wherein the co-curing (1300) is performed in an autoclave.

29. The method according to claim 1 (1000), wherein the co-curing (1300) is carried out to achieve a degree of curing of at least 90 percent.

30. The method according to claim 1 (1000), further comprising placing the carbon-reinforced composite material (2100) on the tool surface (2501) of a tool (2500) (1102) before bringing the glass-reinforced composite material (2200) into contact with the carbon-reinforced composite material (2100) (1202).

31. The method according to claim 1 (1000), wherein the composite material structure (2000) further includes an interface (2005) between the carbon-reinforced composite material component (2010) and the glass-reinforced composite material component (2020), and the interface (2005) includes a single crosslinking phase.

32. A method (1001) for manufacturing a composite structure (2000) including carbon-reinforced composite components (2010) and glass-reinforced composite components (2020), The method involves bringing a glass-reinforced composite material (2200) into contact with a carbon-reinforced composite material (2100) (1201) to produce a composite material layup (2300), wherein the glass-reinforced composite material (2200) comprises a glass-reinforced material (2220) and a polymer matrix material (2210), and the glass-reinforced material (2220) has a silica content of at least 60 weight percent, and the method of producing a composite material layup (2300), and A method (1001) comprising co-fixing the composite material layup (2300) (1301).

33. The method according to claim 32 (1001), wherein the glass reinforcing material (2220) includes glass fibers.

34. The method according to claim 32 (1001), wherein the glass reinforcing material (2220) has a silica content of at least 64 percent.

35. The method according to claim 32 (1001), wherein the glass reinforcing material (2220) has a silica content of at least 80 percent.

36. The method according to claim 32 (1001), wherein the glass reinforcing material (2220) has a silica content of at least 99 percent.

37. The method according to claim 32 (1001), wherein the glass reinforcing material (2220) has a thermal expansion coefficient between approximately 0.1 μm / m°C and approximately 4 μm / m°C.

38. The method according to claim 32 (1001), wherein the glass reinforcing material (2220) has a thermal expansion coefficient of at least 0.5 μm / m°C.

39. The method according to claim 32 (1001), wherein the glass reinforcing material (2220) has a maximum thermal expansion coefficient of 4 μm / m°C.

40. The method according to claim 32 (1001), wherein the polymer matrix material (2210) of the glass-reinforced composite material (2200) comprises a thermoplastic material.

41. The method according to claim 40 (1001), wherein the thermoplastic material comprises at least one of polyetherketone ketone (PEKK), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), and polyetherimide (PEI).

42. The method according to claim 32 (1001), wherein the carbon-reinforced composite material (2100) comprises a carbon-reinforced material (2120) and a polymer matrix material (2110).

43. The method according to claim 42 (1001), wherein the carbon-reinforced material (2120) has a maximum coefficient of thermal expansion (CTE) of 2 μm / m°C.

44. The method according to claim 42 (1001), wherein the carbon-reinforced material (2120) has a maximum thermal expansion coefficient (CTE) of 1.5 μm / m°C.

45. The method according to claim 42 (1001), wherein the carbon-reinforced material (2120) has a maximum thermal expansion coefficient (CTE) of 1 μm / m°C.

46. The method according to claim 42 (1001), wherein the polymer matrix material (2110) of the carbon-reinforced composite material (2100) comprises a thermoplastic material.

47. The method according to claim 46 (1001), wherein the thermoplastic material comprises at least one of polyetherketone ketone (PEKK), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), and polyetherimide (PEI).

48. The method according to claim 42 (1001), wherein the polymer matrix material (2110) of the carbon-reinforced composite material (2100) and the polymer matrix material (2210) of the glass-reinforced composite material (2200) are compositionally the same.

49. The method according to claim 42 (1001), wherein the polymer matrix material (2110) of the carbon-reinforced composite material (2100) and the polymer matrix material (2210) of the glass-reinforced composite material (2200) are compositionally different.

50. The method according to claim 42 (1001), wherein the thermal expansion coefficient of the glass-reinforced material (2220) is between approximately 30 percent and approximately 200 percent of the thermal expansion coefficient of the carbon-reinforced material (2120).

51. The method according to claim 42 (1001), wherein the thermal expansion coefficient of the glass-reinforced material (2220) is between approximately 35 percent and approximately 150 percent of the thermal expansion coefficient of the carbon-reinforced material (2120).

52. The glass-reinforced composite material (2200) has an average cross-sectional thickness (T) between approximately 0.02 inches and approximately 0.1 inches. 1 The method according to claim 32 (1001), having ).

53. The carbon-reinforced composite material (2100) has the average cross-sectional thickness (T) of the glass-reinforced composite material (2200). 1 ) is at least 10 times greater than the average cross-sectional thickness (T 2 The method according to claim 32 (1001), having ).

54. The method according to claim 32 (1001), wherein the co-fixing (1301) is performed in an autoclave.

55. The method according to claim 32 (1001), wherein the composite material structure (2000) further includes an interface (2005) between the carbon-reinforced composite material component (2010) and the glass-reinforced composite material component (2020), and the interface (2005) includes a single co-bonded phase.

56. A method (1000) for manufacturing a composite structure (2000) including carbon-reinforced composite components (2010) and glass-reinforced composite components (2020), The method involves bringing a glass-reinforced composite material (2200) into contact with a carbon-reinforced composite material (2100) (1200) to produce a composite material layup (2300), wherein the glass-reinforced composite material (2200) comprises a glass-reinforced material (2220) and a polymer matrix material (2210), and the carbon-reinforced composite material (2100) comprises a carbon-reinforced material (2120) and a polymer matrix material (2110), and the method involves producing a composite material layup (2300), and The process includes co-curing the composite material layup (2300) (1300), The glass-reinforced material (2220) has a low coefficient of thermal expansion (CTE) substantially matching that of the carbon-reinforced material (2120), thereby minimizing residual stress that causes warping (4000) during the co-curing (1300), method (1000).

57. A composite material structure (2000), Carbon-reinforced composite parts (2010), and The carbon-reinforced composite component (2010) includes a glass-reinforced composite component (2020) connected to the carbon-reinforced composite component (2010), The glass-reinforced composite component (2020) comprises a glass-reinforced material (2220) and a polymer matrix material (2210), wherein the glass-reinforced material (2220) has a low coefficient of thermal expansion, and the composite structure (2000) is also provided.

58. The glass reinforcing material (2220) has a high silica content, as described in claim 57, for the composite material structure (2000).

59. The composite material structure (2000) according to claim 57, wherein the glass reinforcing material (2220) has a silica content of at least 60 weight percent.

60. The composite material structure (2000) according to claim 57, wherein the glass reinforcing material (2220) has a silica content of at least 80 weight percent.

61. The composite material structure (2000) according to claim 57, wherein the glass reinforcing material (2220) has a silica content of at least 99 weight percent.

62. The composite material structure (2000) according to claim 57, further comprising an interface (2005) between the carbon-reinforced composite material component (2010) and the glass-reinforced composite material component (2020), wherein the interface (2005) comprises a single crosslinking phase.

63. The composite structure (2000) according to claim 57, further comprising an interface (2005) between the carbon-reinforced composite component (2010) and the glass-reinforced composite component (2020), wherein the interface (2005) comprises a single co-bonded phase.