Co-Cured UV-Resistant Composite Layer for Aircraft Assembly
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Solution Overview
Problem
Existing composite materials used in structural components, such as aircraft, require multiple protective coatings to resist UV/visible light degradation, which are labor-intensive, time-consuming, and add significant weight, and their removal often damages the underlying material.
Innovation Solution
Incorporating a co-curable and co-cured UV/visible light-resistant layer directly onto the composite material substrate, eliminating the need for separate protective coatings by providing inherent UV/visible light resistance through a single ply layer that is co-cured with the composite material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple separate protective coating layers are applied to composite material substrates to resist UV/visible light degradation, then UV/visible light protection is improved, but device complexity, manufacturing time, and weight increase
Solution Approach 1:
The patent combines multiple separate protective coating layers (UV/visible light-resistant layer and clear coat layer) into a single integrated co-curable coating layer that provides both UV/visible light protection and clear coat functions simultaneously, thereby reducing device complexity while maintaining protective reliability
Solution Approach 2:
The co-curable coating layer is designed to perform multiple functions simultaneously: UV/visible light resistance, clear coat protection, and adhesion promotion, eliminating the need for separate specialized layers and simplifying the overall coating system
2Reliability
If multiple separate protective coating layers are applied to composite material substrates, then UV/visible light protection is improved, but manufacturing time and labor intensity increase
Solution Approach 1:
The patent merges the application and curing processes of multiple coating layers into a single co-curing operation, reducing the number of manufacturing steps and improving productivity while maintaining comprehensive UV/visible light protection
Solution Approach 2:
The coating layers are pre-formulated with compatible curing chemistries that allow them to cure simultaneously in a single step, eliminating the need for sequential curing operations and reducing manufacturing time
3Reliability
If multiple separate protective coating layers are applied to composite material substrates, then UV/visible light protection is improved, but the weight of the composite assembly increases
Solution Approach 1:
The patent combines multiple protective layers into a single integrated coating layer that provides equivalent or superior UV/visible light protection with reduced total material mass, thereby decreasing the weight of the composite material assembly
4Reliability
If separate protective coating layers are applied to composite material substrates, then UV/visible light protection is improved, but removal of coating layers damages the underlying composite material
Solution Approach 1:
The patent creates a unified co-cured coating structure where all protective functions are integrated into a single layer that can be removed as one unit, preventing the progressive damage that occurs when removing multiple separate layers and reducing the risk of underlying composite material damage
5Reliability
If multiple separate protective coating layers are applied to composite material substrates, then UV/visible light protection is improved, but rework time and material costs increase
Solution Approach 1:
The patent integrates multiple protective functions into a single co-curable coating layer, so that when rework is needed, only one layer needs to be removed and reapplied instead of multiple separate layers, significantly reducing rework time and material consumption
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 approach reduces manufacturing complexity, weight, and rework time, while maintaining UV/visible light protection, thereby decreasing material and labor costs and improving the performance of composite materials in structural assemblies.
Implementation Method 1
the co-curable UV/visible light-resistant layer has a co-curable UV/visible light transmittance value ranging from about 0% to about 20% UV/visible light transmittance for UV/visible light wavelengths ranging from about 200 nm to about 800 nm
Implementation Method 2
a co-curable composite material assembly is disclosed comprising a co-curable composite material substrate... and a co-curable UV/visible light-resistant layer... wherein the co-curable UV/visible light-resistant layer has a co-curable UV/visible light transmittance value
Data Source
AI summary
Co-curable and co-cured UV/visible light-resistant composite materials are disclosed with UV/visible light protection exclusively imparted to a co-curable composite material substrate assembly by a co-curable UV/visible light-resistant layer disposed to cover the co-curable and co-cured composite material substrate.