Applique

• US 20050181203A1
• Filed: 09/15/2004
• Published: 08/18/2005
• Est. Priority Date: 09/30/2003
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Rawlings, Diane C., Keough, Bruce K.
• Granted Patent: US 8,715,824 B2
• Time in Patent Office: Days
• US Class Current: 428/337
• CPC Class Codes: B29C 59/14 by plasma treatment plasma tubes per se H01J
• CPC Class Codes: B32B 15/08 of synthetic resin
• CPC Class Codes: B32B 15/085 comprising polyolefins
• CPC Class Codes: B32B 15/088 comprising polyamides
• CPC Class Codes: B32B 15/09 comprising polyesters
• CPC Class Codes: B32B 15/095 comprising polyurethanes
• CPC Class Codes: B32B 15/20 comprising aluminium or copper B32B15/016 and B32B15/017 take precedence
• CPC Class Codes: B32B 2262/103 Metal fibres
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/21 Anti-static
• CPC Class Codes: B32B 2310/14 Corona, ionisation, electrical discharge, plasma treatment
• CPC Class Codes: B32B 2311/24 Aluminium
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2377/00 Polyamides
• CPC Class Codes: B32B 2605/18 Aircraft blades, propellers B32B2603/00
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 27/281 comprising polyimides
• CPC Class Codes: B32B 27/286 comprising polysulphones; polysulfides
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 38/0008 Electrical discharge treatment, e.g. corona, plasma treatment; wave energy or particle radiation heat treatment B32B38/0036
• CPC Class Codes: B44C 1/105 : comprising an adhesive layer decalcomania B44C1/16; adhesive tapes C09J7/20
• CPC Class Codes: B64C 1/12 : Construction or attachment of skin panels
• CPC Class Codes: B64C 3/26 : Construction, shape, or attachment of separate skins, e.g. panels
• CPC Class Codes: B64D 45/02 : Lightning protectors; Static dischargers in general H01T
• CPC Class Codes: Y10T 428/266 : of base or substrate
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31681 : Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31688 : Next to aldehyde or ketone condensation product
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers

Abstract

According to a non-limiting embodiment of the present invention, an appliqué coating is provided for a substrate. The appliqué coating includes a metal foil and a first polymer film underlying the metal foil. A topcoat overlying the metal foil may be provided as a layer of paint or as a second polymer film. An adhesive, such as a pressure sensitive adhesive, underlying the first polymer film may be provided to affix the appliqué coating to the substrate. If desired, fibers may be dispersed throughout the second polymer film to provide anti-static properties. Also, an ink layer may be provided between the metal foil and the second polymer film, if desired, for aesthetic and/or anti-static purposes.

Claims

1. An appliqué

coating for a substrate, the coating comprising;

a metal foil; and

a polymer film underlying the metal foil.

2. The coating of claim 1, wherein the metal foil includes aluminum foil.

3. The coating of claim 1, wherein the metal foil has a thickness between around 0.1 mil and around 0.75 mil.

4. The coating of claim 3, wherein the metal foil has a thickness between around 0.25 mil and around 0.5 mil.

5. The coating of claim 1, wherein the metal includes one of copper, nickel, gold, and titanium.

6. The coating of claim 1, wherein the polymer film includes nylon.

7. The coating of claim 1, wherein the polymer film includes at least one of poly ether ether ketone (PEEK), polysulfonate, polyester, polyamide, polyimide, polyolefin, polyurethane and, halopolymer.

8. The coating of claim 1, wherein the polymer film includes a two-layer polymer film combination.

9. The coating of claim 8, wherein the two-layer polymer film combination includes one of a polyester/polyethylene combination, a PEEK/polyethylene combination, a PEEK/nylon combination, and a polyester/nylon combination.

10. The coating of claim 1, wherein the polymer film is arranged to be affixed to a substrate, the substrate including a skin of an aircraft.

11. The coating of claim 1, further comprising a layer of paint covering the metal foil.

12. The coating of claim 11, wherein the metal foil is treated with one of a conversion coating, electrodeposition, adhesive, primer, and sol-gel.

13. The coating of claim 1, further comprising a maskant overlying the metal foil.

14. The coating of claim 1, wherein at least one of the metal foil and the polymer film is plasma treated.

15. The coating of claim 1, further comprising an adhesive underlying the polymer film.

16. The coating of claim 15, wherein the adhesive includes a pressure sensitive adhesive.

17. An appliqué

coating for a substrate, the coating comprising;

a metal foil;

a first polymer film underlying the metal foil; and

a second polymer film overlying the metal foil and configured as a topcoat.

18. The coating of claim 17, wherein the second polymer film includes polyurethane.

19. The coating of claim 18, wherein the second polyurethane is cast with a solvent.

20. The coating of claim 17, wherein the second polymer film includes at least one of halopolymer, epoxy, fluorosilicone, polyester, polyolefin, polyamide, polyimide, polyurethane and poly ether ether ketone (PEEK), and polyurea.

21. The coating of claim 17, further comprising a plurality of fibers dispersed throughout the second polymer film.

22. The coating of claim 21, wherein the fibers include at least one of graphite fibers and metal fibers.

23. The coating of claim 17, further comprising a third polymer film disposed between the second polymer film and the metal foil.

24. The coating of claim 23, wherein the third polymer film includes at least one of polyolefin, halopolymer, epoxy, fluorosilicone, polyester, polyamide, polyimide, polyurethane, poly ether ether ketone (PEEK), and polyurea.

25. The coating of claim 17, further comprising a layer of ink.

26. The coating of claim 25, wherein the layer of ink is disposed between the second polymer film and the metal foil.

27. The coating of claim 17, wherein the first polymer film is arranged to be affixed to a substrate, the substrate including a skin of an aircraft.

28. The coating of claim 17, further comprising an adhesive underlying the first polymer film.

29. The coating of claim 28, wherein the adhesive includes a pressure sensitive adhesive.

30. The coating of claim 17, further comprising a layer of paint covering the second polymer film.

31. An appliqué

coating for a substrate, the coating comprising;

a metal foil;

a first polymer film underlying the metal foil, the first polymer film including one of nylon, PEEK, a two-layer polyester/nylon combination, a two layer PEEK/polyethylene combination, a two-layer PEEK/nylon combination, and a two-layer polyester/polyethylene combination; and

a second polymer film configured as a topcoat, the second polymer film including polyurethane cast with a solvent.

32. The coating of claim 31, wherein the metal foil includes aluminum foil.

33. The coating of claim 32, wherein the aluminum foil has a thickness between around 0.25 mil and around 0.5 mil.

34. The coating of claim 31, wherein the first polymer film is arranged to be affixed to a substrate, the substrate including a skin of an aircraft.

35. The coating of claim 31, further comprising an adhesive underlying the first polymer film.

36. The coating of claim 35, wherein the adhesive includes a pressure sensitive adhesive.

37. A method of forming an appliqué

coating for a substrate, the method comprising;

providing a metal foil; and

providing a first polymer film underlying the metal foil.

38. The method of claim 37, further comprising providing a topcoat overlying the metal foil.

39. The method of claim 38, wherein providing a topcoat includes providing at least one of a second polymer film overlying the metal foil and a layer of paint covering the metal foil.

40. The method of claim 39, further comprising plasma treating at least one of the first polymer film, the metal foil, and the second polymer film.

41. The method of claim 39, further comprising dispersing a plurality of fibers throughout the second polymer film.

42. The method of claim 41, wherein the fibers include at least one of graphite fibers and metal fibers.

43. The method of claim 39, further comprising providing a third polymer film disposed between the second polymer film and the metal foil.

44. The method of claim 39, further comprising providing an ink layer.

45. The method of claim 39, wherein providing a topcoat includes covering the second polymer film with paint.

46. The method of claim 39, further comprising treating the metal foil with one of a conversion coating, electrodeposition, adhesive, primer, and sol-gel.

47. The method of claim 37, further comprising providing a maskant overlying the metal foil.

48. The method of claim 37, further comprising providing an adhesive underlying the first polymer film.

49. The method of claim 37, wherein the first polymer film includes a two-layer polymer film combination including one of a polyester/polyethylene combination, a PEEK/polyethylene combination, a PEEK/nylon combination, and a polyester/nylon combination.

50. An aircraft comprising:

a pair of wings, each of the wings having skin;

at least one engine;

a fuselage having skin;

control surfaces having skin; and

an appliqué

coating adhesively attached to a portion of the skin, the coating including;

a metal foil; and

a first polymer film underlying the metal foil.

51. The aircraft of claim 50, wherein the coating further includes a topcoat overlying the metal foil.

52. The aircraft of claim 51, wherein the topcoat includes a second polymer film overlying the metal foil.

53. The aircraft of claim 51, wherein the topcoat includes a layer of paint covering the metal foil.

54. The aircraft of claim 52, further comprising a layer of paint covering the second polymer film.

55. The aircraft of claim 50, further comprising an adhesive underlying the first polymer film.

56. The aircraft of claim 50, wherein the first polymer film includes a two-layer polymer film combination including one of a polyester/polyethylene combination, a PEEK/polyethylene combination, a PEEK/nylon combination, and a polyester/nylon combination.

57. An appliqué

coating assembly for a substrate having a fastener extending therethrough, the coating assembly comprising;

an appliqué

coating; and

a dielectric layer underlying the appliqué

coating, the dielectric layer being arranged to be interposed between the appliqué

coating and a head of a fastener that extends through a substrate.

58. The assembly of claim 57, wherein the appliqué

coating includes;

a metal foil; and

a polymer film underlying the metal foil.

59. The assembly of claim 57, wherein the dielectric layer includes a polymer film layer.

60. A structure comprising:

a panel; and

an appliqué

coating attached to a portion of a surface of the panel, the coating including;

a metal foil; and

a first polymer film underlying the metal foil.

61. The structure of claim 60, wherein the coating further includes a topcoat overlying the metal foil.

62. The structure of claim 61, wherein the topcoat includes a second polymer film overlying the metal foil.

63. The structure of claim 61, wherein the topcoat includes a layer of paint covering the metal foil.

64. The structure of claim 62, further comprising a layer of paint covering the second polymer film.

65. The structure of claim 60, further comprising an adhesive underlying the first polymer film.

66. The structure of claim 60, wherein the panel includes a composite panel.

67. The structure of claim 66, wherein the composite panel includes a fiber-reinforced resin composite panel.

68. The structure of claim 60, wherein the panel includes a metal panel.

69. A method for protecting a substrate against damage from electrical energy, the method comprising:

providing a substrate;

providing a metal foil; and

providing a first polymer film between the metal foil and the substrate.

70. The method of claim 69, further comprising providing a topcoat overlying the metal foil.

71. The method of claim 70, wherein providing a topcoat includes providing at least one of a second polymer film overlying the metal foil and a layer of paint covering the metal foil.

72. The method of claim 71, further comprising plasma treating at least one of the first polymer film, the metal foil, and the second polymer film.

73. The method of claim 71, further comprising dispersing a plurality of fibers throughout the second polymer film.

74. The method of claim 73, wherein the fibers include at least one of graphite fibers and metal fibers.

75. The method of claim 71, further comprising providing a third polymer film disposed between the second polymer film and the metal foil.

76. The method of claim 71, further comprising providing an ink layer.

77. The method of claim 71, wherein providing a topcoat includes covering the second polymer film with paint.

78. The method of claim 77, further comprising treating the metal foil with one of a conversion coating, electrodeposition, adhesive, primer, and sol-gel.

79. The method of claim 69, further comprising providing a maskant overlying the metal foil.

80. The method of claim 69, further comprising providing an adhesive underlying the first polymer film.

81. The method of claim 69, wherein the composite substrate is provided as part of a composite vehicle.

82. The method of claim 69, wherein the first polymer film includes a two-layer polymer film combination including one of a polyester/polyethylene combination, a PEEK/polyethylene combination, a PEEK/nylon combination, and a polyester/nylon combination.