Appeal No. 2006-0551 Παγε 4
Application No. 10/182,904
Westre discloses methods of producing hybrid laminates for use as aircraft skin
components. The hybrid laminates of Westre's invention include spaced-apart layers of
a metallic foil, with a layer or layers of an organic polymeric matrix composite. Foils of
titanium or titanium alloy are preferred for use as the metallic foil. Each layer of organic
composite is made up of at least one ply including an organic polymeric resin within
which are embedded parallel reinforcing fibers. While the fibers within each ply of
organic composite are parallel, the fibers of one ply may be at right angles, or any other
angle, to the fibers in another ply of organic composite of the hybrid laminate.
According to Westre (column 7, line 58, to column 8, line 30),
[t]he hybrid laminates may be made by any of a number of
methods. However, in the case of thermoplastic composites,
it is preferred that the laminates are prepared by
successively laying down long continuous strips of
thermoplastic resin preimpregnated fibrous tapes
("prepregs"), by means of a thermoplastic application head,
directly onto the treated outer surface of a foil. By laying
down strips of tape side-by-side while consolidating these
through the application of heat and pressure, a continuous
ply of composite with parallel-oriented fibers is produced.
Thereafter, another ply or plies of composite may be laid
down on top of the first ply, depending upon the properties
needed of the laminate. The ply or plies make up a layer of
composite. Then, a layer of foil is rolled out over the
consolidated composite layer and is bonded, for example
heat-fused, onto the composite. Thereafter, a next layer of
organic composite is formed on top of the metallic foil by
laying down a ply or plies, as described above. Finally, after
laying down the predetermined number of layers of metallic
foil and organic polymeric matrix, an outer layer of metallic
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