| US 7,491,289 B2 | ||
| Methods of forming metal foil ply replacement in composite structures | ||
| Willard N. Westre, Bellevue, Wash. (US); David W Evans, Kent, Wash. (US); Edward Li, Seattle, Wash. (US); Marc J. Piehl, Renton, Wash. (US); and Eric Sager, Seattle, Wash. (US) | ||
| Assigned to The Boeing Company, Chicago, Ill. (US) | ||
| Filed on Sep. 11, 2006, as Appl. No. 11/530,582. | ||
| Application 11/530582 is a continuation of application No. 10/650231, filed on Aug. 28, 2003, granted, now 7,115,323. | ||
| Prior Publication US 2007/0000596 A1, Jan. 04, 2007 | ||
| Int. Cl. B29C 65/00 (2006.01); B32B 37/00 (2006.01); B32B 3/00 (2006.01); H05K 13/04 (2006.01); E04F 13/08 (2006.01); B64C 1/00 (2006.01) | ||
| U.S. Cl. 156—300 [156/293; 156/297; 156/298; 156/299; 156/304.1; 428/58; 244/133] | 20 Claims |
| 1. A method of laying up a laminate structure, the method comprising:
forming a metal-polymer composite layer of substantially uniform thickness that non-interruptedly extends from a first face
to a second face, the metal-polymer composite layer including:
a first portion of non-metallic material including a first resin, the first portion interrupted by the presence of a first
cutout; and
a second portion of metallic material including a second resin, the second portion substantially filling the first cutout
of the first portion, and the second resin being different from the first resin;
forming a fiber-reinforced polymeric layer, the fiber-reinforced polymeric layer non-interruptedly extending from the first
face to the second face along the metal-polymer composite layer;
coupling the fiber-reinforced polymeric layer adjacent to the metal-polymer composite layer;
forming a metal layer, the metal layer interruptedly extending along a portion of the fiber-reinforced polymeric layer from
a third face to fourth face such that the laminate structure is of non-uniform thickness; and
coupling the metal layer adjacent to the fiber-reinforced polymeric layer.
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