Co-curable Film Layer Application for Composite Marking
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Solution Overview
Problem
Marking composite materials used in aerospace components, such as aircraft, is challenging due to increased manufacturing time and costs associated with traditional painting methods, which require multiple steps and can compromise aerodynamic performance and surface smoothness.
Innovation Solution
A method involving the application of multiple co-curable film layers with different color markings that are co-cured with the composite structure in a single process, eliminating the need for additional steps like masking and multiple curing, and potentially including a clearcoat layer for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional painting methods are used to mark composite structures, then color markings can be applied, but manufacturing time and costs increase due to multiple steps including masking, painting, and demasking
Solution Approach 1:
The patent combines multiple painting operations into a single co-curing process. Multiple colored film layers are applied to the composite structure simultaneously and cured together in one step, eliminating the need for sequential masking, painting, and demasking operations that were required in traditional methods.
Solution Approach 2:
The patent applies colored film layers to the composite structure before the final curing step. The films are positioned and prepared in advance, then all layers are cured simultaneously in a single operation, preventing the need for repeated masking and demasking cycles.
2Manufacturing precision
If multiple layers of paint are applied to create multi-color designs, then color markings can be achieved, but surface smoothness and aerodynamic performance deteriorate due to coating edges and waviness
Solution Approach 1:
The patent uses thin film layers instead of traditional thick paint coatings. These films conform to the composite structure's surface and can be made extremely thin, eliminating the coating edges, peaks, and waviness that occur with multiple thick paint layers while maintaining color definition.
Solution Approach 2:
The patent applies different colored films only where needed on the composite structure rather than coating entire surfaces. This localized application eliminates unnecessary coating edges and maintains surface smoothness in areas where color markings are not required.
3Reliability
If traditional paint coatings are applied to protect composite structures, then environmental protection can be provided, but coating thickness and weight increase
Solution Approach 1:
The patent uses thin film coatings that provide environmental protection while minimizing thickness and weight. The films are applied in thin layers and cured to form a protective barrier against environmental conditions without the substantial weight increase associated with traditional multi-layer paint systems.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces processing time and costs while achieving a smooth, aerodynamic surface with enhanced durability against environmental conditions, including UV radiation and chemicals, and provides a weight savings by minimizing coating thickness and edge peaks.
Implementation Method 1
curing the lay-up of the multi-colored marking and the composite to create a cured multi-colored coating on the composite structure
Data Source
AI summary
The present disclosure is directed to a method for applying a multi-colored coating to a composite structure comprising applying a first co-curable film layer comprising a first color marking to a composite tool, applying a second co-curable film layer comprising a second color marking over the composite tool and at least partially over the first co-curable film layer to create a lay-up of a multi-colored marking, applying a composite structure over the lay-up of the multi-colored marking, and curing the lay-up of the multi-colored marking and the composite structure in a single curing step to create a cured multi-colored coating on the composite structure. A multi-colored coating for marking a composite structure and an aircraft part having a multi-colored marking are also provided.