Metalized Composite Laminates Using a Thermoplastic Interlayer

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Solution Overview

Problem

Existing metallization techniques for thermoset composites in aerospace and automotive applications face challenges such as erosion and surface degradation during cold spraying, necessitating a more robust and efficient method for fabricating multilayered composite materials with improved EMI resistance and lightning protection.

Innovation Solution

A process involving cold spraying metal particles onto a thermoplastic polymer layer, followed by curing, to form a metallic coating that is integrated into a multilayer composite structure, using thermosetting and thermoplastic polymers like PEEK and PEKK, which can withstand high temperatures and pressures without detrimental effects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If cold spray processing is used to deposit metal layers on thermoset composites, then metallization is achieved, but erosion and surface degradation occur

Engineering Contradiction:

Improvemetallization qualityVSAvoiderosion and surface degradation

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

A thermoplastic polymer layer is introduced as an intermediary between the thermoset composite substrate and the cold-sprayed metal layer. This intermediate layer accepts the metal coating without the erosion issues that affect direct thermoset metallization, thereby protecting the underlying thermoset composite while achieving reliable metallization.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention creates a composite structure combining thermoset polymer material with a thermoplastic polymer layer. This composite approach leverages the advantages of both material types: the thermoset provides structural properties while the thermoplastic layer provides a suitable surface for metal deposition that resists erosion.

Inventive Principle:

Principle #40Composite materials

2Strength

If thermoset composite materials are used for aerospace applications, then structural performance is achieved, but erosion during metallization occurs

Engineering Contradiction:

Improvestructural performanceVSAvoiderosion during cold spray

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The composite structure is segmented into distinct functional layers: a thermoset polymer substrate providing structural performance and a separate thermoplastic polymer layer providing erosion-resistant metallization surface. This segmentation allows each layer to optimize its specific function without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The thermoplastic polymer layer serves as a protective intermediary that shields the thermoset structural composite from the harmful effects of cold spray processing, allowing metallization to proceed without eroding the underlying structural material.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If direct metallization of thermoset composites is performed, then metal layer deposition is achieved, but adhesion and durability are compromised

Engineering Contradiction:

Improvemetal layer depositionVSAvoidadhesion and durability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The thermoplastic polymer layer acts as a mediating interface that improves adhesion between the metal coating and the composite substrate. This intermediate layer provides a surface that bonds well with both the thermoset composite and the cold-sprayed metal, enhancing overall durability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

The method provides a robust, metallized composite material with excellent adhesion, improved electrical conductivity, and enhanced strength, addressing erosion issues and enhancing EMI resistance and lightning protection.

Implementation Method 1

cold sprayed metal layer present on at least a portion of a surface of the thermoplastic polymer layer

Methodology Applied

Scientific EffectCold spray:

Implementation Method 2

heating the gas to a temperature below a melting point of the metal particles

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 3

flowing the heated gas through a nozzle, thereby heating and compressing the gas to accelerate a flow of the metal particles

Methodology Applied

Scientific EffectCompressed gas flow:

Implementation Method 4

curing the multilaminate thermosetting polymer structure

Methodology Applied

Scientific EffectCuring: Heat Treatment

Data Source

PatentEP4238753B1Composite laminates with metal layers and methods thereof

Publication Date: 2026.05.06 THE BOEING CO

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AI summary

A multilayered article is disclosed, the multilayered article including a thermosetting polymer material having at least one surface, a thermoplastic polymer layer deposited on the at least one surface of the thermosetting polymer material, a cold sprayed metal layer present on at least a portion of a surface of the thermoplastic polymer layer, at least one additional layer, the at least one additional layer sandwiching at least a portion of the cold sprayed metal layer between the additional layer and the thermoplastic polymer layer, where the thermoplastic polymer layer has a crystallinity of about 5% to about 60%. A method of providing a composite laminate structure is also disclosed.