Appeal 2007-0906
Application 10/445,238
Appellants acknowledge that composites are used in a variety of
applications and industries, such as in the aerospace or shipping industries
for fashioning composite structural elements used for the exterior of aircrafts
and ships (Specification 1). Such composite structures are subject to
degradation due to their environmental exposure (id.). Coatings are applied
to the composite components to mitigate exposure and resulting damage
thereto (id.). Appellants’ claimed invention is directed to an alleged
improvement in a method of coating a composite structure with a liquid
crystal polymer (LCP), wherein a layer of the LCP is applied to a tool, a
layer of a composite material applied to the LCP layer, the layers cured, and
the layers removed from the tool. In such a method, Appellants employ a
multi-axially oriented LCP having a specified softening temperature that is
not substantially greater than the temperature at which the layers are cured
(Specification 3). According to Appellants, use of such an LCP may allow
for better conformation of the LCP to the shape of the composite surface
while curing at a temperature at which heat-induced damage to the coated
composite is avoided (Specification 6). Appealed claims 1 and 4 are
illustrative and reproduced below:
1. A method for thermoplastic coating a composite structure,
comprising: applying a release agent on a working surface of a tool;
applying a layer of crystalline multi-axially oriented liquid crystal
polymer having a softening temperature of about 110ºC to 120ºC onto the
working surface;
applying a layer of composite material onto the crystalline multi-
axially oriented liquid crystal polymer layer;
2
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