Patent ID: 12260968

REFERENCE NUMBERS

metal-mesh gaskets 10dry metal-mesh gasket 12resin 14infused metal-mesh gaskets 16composite structure 18wall 20flange 22flange face 24(co-cured) infusedinterface surface 28metal gasket 26co-cured region 30copper wire mesh layer 32other layer(s) 34metal-coated carbon fibercomposite layer 36lightweight conductive layer 37structural layer 38wall surface layer 40metal-wire mesh layer 42interface region 44stepped flange 46transverse edge 48light-weight structural layer 50additional metal-mesh gasket 52upper component 54lower component 56combination composite structure 58non-planar roughed surface 60(exposed) metal threads 62resilient resin 64internal void 66

DETAILED DESCRIPTION OF THE INVENTION

The presently preferred embodiments of the invention will be best understood by reference to the figures (photographic depictions and drawings), wherein like parts are designated by like numerals throughout. It will be readily understood that the aspects of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the present invention, as represented in the figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of presently preferred embodiments of the invention.

The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. While the various aspects of the embodiments are presented in drawings, the drawings are not necessarily drawn to scale unless specifically indicated.

FIG.1is a photographic depiction of exemplary metal-mesh gaskets10. Depicted is an exemplary dry metal-mesh gasket12on the left side of the photograph. The remaining metal-mesh gaskets10shown are infused with a resin14to form exemplary infused metal-mesh gaskets16. The term “metal-mesh gasket” is meant to include any type of metal-mesh gasket10, including highly conductive, metal-braided (or metal-knitted) gaskets, as mentioned above. The type of metal used may be any metal that exhibits suitable conductivity for the gasket's intended purpose. Additionally, the metal used in the metal-mesh gaskets10may be selected from those metals that exhibit better corrosion resistance than, for example, copper or any other metal that is more susceptible to corrosion that may be included as a highly conductive, metal wire mesh layer in a composite structure. Resilient resin64is shown representatively inFIG.1but is discussed below in the discussion regardingFIG.9.

FIG.2is another photographic depiction. It is a vertical section of an exemplary, multi-component composite structure18having a substantially vertical wall20and a substantially horizontal flange22formed therein to define a flange face24and comprising an infused metal gasket26co-cured onto the flange face24. Infused metal gasket26co-cured onto the flange face24has a conductive interface surface28. The representative composite structure18depicted comprises a co-cured region30, a copper wire mesh layer32, and other layer(s)34such as a metal-coated carbon fiber composite layer36, and a representative structural layer38that may or may not be a wall surface layer40. Of course, the number of layers, the types of layers, the conductivity of the layers, the juxtaposition of various layers, and the various other composite variables and considerations may be altered and adjusted to create a composite structure18with various desired attributes to meet the desired needs for the composite structure18. For example, the composite structure18depicted has a copper wire mesh layer32, but other contemplated composite structures18may use a wire mesh comprising a metal other than copper, forming a metal-wire mesh layer42or may not have any metal-wire mesh layer42.

Many types of composite structures are known, and desired composite attributes may be achieved by combining various layers with various characteristics. Heretofore the challenge of creating a robust, highly conductive interface region44with enhanced interface surface(s)28that protect(s) metal wire mesh layer(s)32,42from corrosion has not been accomplished. However, by co-curing an infused metal-mesh gasket16with a composite layup, not only is the highly conductive interface surface28achieved, but manufacturing is streamlined by combining otherwise multiple steps into a single, simple co-curing manufacturing step that eliminates gasket tear off or vulnerability issues, non-conductive resin face issues, and electromagnetic shielding leakage from the interface region44. Exposed metal threads62are depicted inFIG.2but are discussed below in reference toFIG.8.

FIG.3is a perspective view of a vertical section of yet another exemplary multi-component composite structure18having a finished interface surface28on a stepped flange46with an infused metal gasket26co-cured on the stepped flange46. The composite structure18ofFIG.3differs from the composite structure18ofFIG.2in that it is trimmed and finished so that it depicts an interface surface28ready for abutting engagement with a complementary trimmed and finished interface surface28.

FIG.4is yet another photographic depiction. It is a top plan view of a transverse edge48of an exemplary conductive multi-component composite structure18showing an exemplary combination of laminate layers, including a co-cured, compressed infused metal gasket26overlayed along the transverse edge48forming an interface surface28.

The representative composite structure18depicted comprises a transversely disposed co-cured metal-mesh gasket26overlayed upon the transverse edge48of the vertically disposed composite layers comprising inside and outside wall surface layers40, a copper wire mesh layer32, and other layers34(the other layers34, shown having a phantom lead line to indicate being beneath a visually obscuring structure, and a portion of the copper wire mesh layer32are not visible because they are obscured by the overlaying co-cured metal-mesh gasket26). Again, of course, the number of layers, the types of layers, the conductivity of the layers, the juxtaposition of various layers, and the various other composite variables and considerations may be altered and adjusted to create a composite structure18with various desired attributes to meet the desired needs for the composite structure18.

A representative exemplary composite structure18having a co-cured conductive metal-mesh gasket26overlayed upon and co-cured upon the transverse edge48of the vertically disposed composite layers of the composite structure18is shown inFIG.5. With this composite structure18, a co-cured region30comprising a portion of the conductive metal-mesh gasket26and a top portion of each of the conductive composite layers define and create at least a portion of a robust, highly conductive interface region44having a highly conductive interface surface28that is corrosion resistant and corrosion protective to any metal wire mesh layer42, particularly the copper wire mesh layer32. This is a principal aspect that has not heretofore been known or achieved.

The other or additional layers34that may be used in the laminate composite structure18may be a light-weight conductive layer37such as a metal-coated carbon fiber composite layer36and/or may be a light-weight structural layer50that may be conductive or not conductive and/or any other layer or layers34. Those skilled in the art of composite laminates know of many potential combinations of other or additional layers34that may be used to achieve other attributes in the composite structure18.

FIG.6is an alternative exemplary conductive composite structure18showing an exemplary combination of laminate layers (the portion to the left of Arrow A-A is a cutaway on a diagonal section taper to reveal the layers of the multi-component composite) and includes a co-cured, compressed conductive infused metal gasket26and an additional metal-mesh gasket52connected to the interface surface28of the co-cured, compressed conductive infused metal gasket26by a suitable connection. Such connection may be accomplished by adhesive bonding, tacking, spot adhesive bonding, co-curing with the other laminate layers, or any other suitable connection.

With the laminate construction shown inFIG.6, the additional metal-mesh gasket52(such as a strip gasket) may be dry (as shown inFIG.1, a dry metal-mesh gasket12) and extend along an edge of an interface surface28and attached by adhesive or other suitable bonding, or the additional metal-mesh gasket52also may be co-cured with the laminate. This type of construction may be used where the interface surface28along the edge may be adequate to accomplish the desired conductivity within the interface region44.

The diagonal section taper portion of the multi-component composite to the left of Arrow A-A reveals an exemplary composite structure18comprising a transversely disposed co-cured metal-mesh gasket26overlayed upon the transverse edge48of the vertically disposed composite layers comprising inside and outside wall surface layers40, a copper wire mesh layer32, and other layers34(the other layers34, for example, may comprise a metal-coated carbon fiber composite layer or lightweight conductive layer36and a structural layer38, as shown). Again, of course, the number of layers, the types of layers, the conductivity of the layers, the juxtaposition of various layers, and the various other composite variables and considerations may be altered and adjusted to create a composite structure18with various desired attributes to meet the desired needs for the composite structure18.

The representative exemplary composite structure18having a co-cured conductive metal-mesh gasket26overlayed upon and co-cured upon the transverse edge48of the vertically disposed composite layers of the composite structure18as shown inFIG.6, has a co-cured region30comprising a portion of the conductive metal-mesh gasket26and a top portion of each of the conductive composite layers define and create at least a portion of a robust, highly conductive interface region44having a highly conductive interface surface28that is corrosion resistant and corrosion protective to any metal wire mesh layer42, particularly the copper wire mesh layer32. This is a principal aspect that has not heretofore been known or achieved.

FIG.7is a side, exploded view of a portion of an exemplary interface region44between an upper component54and a lower component56(such as a lid and an enclosure) showing an infused metal-mesh gasket16co-cured on transverse edges (faces)48of the upper and lower components54,56of representative composite structures18. The positions of the upper and lower components54,56are shown prior to or after the upper and lower components54,56are brought into or out of abutting engagement with each other. The respective interface surfaces28are non-planar having complementary mating contours. Complementary mating contours, when in abutting mated engagement, create a contact interface and provide enhanced conductivity to eliminate or drastically reduce electromagnetic shielding leakage within the interface region44.

FIG.8is a sectional, exploded view of a portion of another exemplary interface region44between an upper component54and a lower component56showing an ablated, infused metal gasket26co-cured on each transverse edge48of the upper and lower components54,56of another representative combination composite structure58. Again, the positions of the upper and lower components54,56are shown prior to or after the upper and lower components54,56are brought into or out of abutting engagement. The interface surface28of each of the upper and lower components54,56within this alternative interface region44is a non-planar roughed surface60. It should be understood, the non-planar roughed surface60shown is exaggerated for illustration purposes. Actual roughing will likely be considerably less pronounced.

The roughing of interface surfaces28may be achieved by scuffing off some or all excess resin14along the interface surface28after curing the resin14. This also may be done using any of several known ablation processes or techniques such as light sanding, scraping, sand blasting, chemical etching, laser ablation or any other technique that removes excess resin14at the interface surface28. By roughing the interface surfaces28, many metal threads62(best seen inFIG.2) of the metal mesh (best seen in the dry metal-mesh gasket12ofFIG.1) of the conductive, infused metal gasket26may be exposed. When each of the opposing interface surfaces28are brought together, many metal thread-to-metal thread contact points (not shown) will be created, thereby enhancing conductivity between the upper and lower components54,56.

FIG.9is a sectional end view of yet another alternative exemplary conductive composite structure18showing an exemplary combination of laminate layers disposed vertically, including an overlayed and co-cured, conductive, infused metal-mesh gasket26where the co-cured, infused metal-mesh gasket26is less than fully compressed, and a resilient resin64is used in curing to give the interface surface28a somewhat compressible, resilient interface surface28. The exemplary conductive composite structure18comprises an exemplary combination of laminate layers, including wall surface layers40, a metal wire mesh layer42(such as a copper wire mesh layer32), three additional layers34that each may be any type of layer that conveys a desired physical attribute (such as, for example as shown, metal-coated carbon fiber composite layer36, a light-weight conductive layer37and a light-weight structural layer38). These additional layers34, if any, may be selected by number of layers, juxtaposition of layers, and type of layers to provide specific attributes to the overall conductive composite structure18, and as discussed above, those skilled in the art of composite laminates know of many combinations of other layers34that may be used to achieve other desired attributes. One or more of these other layers34may be conductive or not conductive. This alternative embodiment depicts a conductive composite structure18where the conductive infused metal gasket26, the metal wire mesh layer32, and any additional layers34are combined into a composite layup that is co-cured.

The co-cured, conductive, infused metal-mesh gasket26shown inFIG.9is attached to the transverse edge48of the combination of vertically disposed laminate layers. As depicted, the infused metal-mesh gasket26is less than fully compressed, thereby leaving an interior void66that facilitates a degree of resiliency in the infused metal-mesh gasket26. To introduce a resilient interface surface28on the conductive composite structure18, a resilient resin64may be infused into the metal mesh of the metal-mesh gasket26and the internal void66, thereby filling the interstices of the metal mesh and the internal void66. Then, by co-curing the resilient resin64, the interface surface28may be somewhat compressible, creating resilient interface surface(s)28while maintaining conductivity.

Manufacturing expediency is achieved by the present invention. By co-curing an infused metal-mesh gasket16together with a composite layup, not only is the highly conductive interface surface28achieved but it combines the securement of the infused metal-mesh gasket16with a simple manufacturing step that is already being performed in creating the laminate. The only real difference is that the step is altered by adding the compressed infused metal-mesh gasket16to the transverse edge48of the combination of vertically disposed laminate layup prior to curing so that the compressed infused metal-mesh gasket16is co-cured with the other laminate layers34. Significantly, this unique method creates a co-cured region30that eliminates gasket tear off or vulnerability issues, non-conductive resin face issues, and electromagnetic shielding leakage within the interface region44. Additionally, the co-curing increases the strength of the bond and eliminates the need for an adhesive (whether the adhesive that would have been used otherwise is conductive or non-conductive) between the gasket and the transverse edge48or the flange face24.

Those skilled in the art will appreciate that the present embodiments are exemplary and should not be limited to the embodiments shown and described.

The present invention may be embodied in other specific forms without departing from its structures, methods, or other essential characteristics as broadly described herein and claimed hereinafter. The described embodiments are to be considered in all respects only as illustrative, and not restrictive. The scope of the invention will, therefore, be indicated by the ultimate claims, rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced within their scope.