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Laminate structures and methods for forming same are disclosed. In one embodiment, a laminate structure includes a metal-polymer composite lamina. The metal-polymer composite lamina has a first face and a second face spaced apart, and extends to a terminal edge. The lamina includes a ply of fiber-r

Laminate structures and methods for forming same are disclosed. In one embodiment, a laminate structure includes a metal-polymer composite lamina. The metal-polymer composite lamina has a first face and a second face spaced apart, and extends to a terminal edge. The lamina includes a ply of fiber-reinforced polymer that extends between the first face and the second face and has an interior edge. The interior edge defines at least one cutout. A ply of metal foil extends between the first face and the second face substantially from the interior edge filling the at least one cutout.

대표청구항 ▼

What is claimed is: 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

What is claimed is: 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. 2. The method of claim 1, wherein the first portion includes a fiber-reinforced polymer selected from a group consisting of aramids, polyolefins, glass, carbon, boron, and ceramics. 3. The method of claim 1, wherein the second portion includes a metal selected from a group consisting of alloys of titanium, alloys of aluminum, and alloys of iron. 4. The method of claim 3, wherein the alloys of titanium are selected from a group consisting of (Ti-6Al-4V), (Ti-15V-3Cr-3Sn-3Al) and (Ti-15Mo-3Al-3Nb). 5. The method of claim 1, wherein the first resin and the second resin are selected from a group consisting of thermosetting resin, a thermoplastic resin, and a hybrid polymer resin. 6. The method of claim 1, wherein the fibers of the metal-polymer composite layer and the fibers of the fiber-reinforced polymeric layer are oriented in a direction selected from the group consisting of approximately zero degrees, approximately ninety degrees, approximately positive forty-five degrees, and approximately negative forty-five degrees. 7. The method of claim 1, further comprising applying an adhesive resin between the metal-polymer composite layer and the fiber-reinforced polymeric layer. 8. The method of claim 7, wherein the adhesive resin between the metal-polymer composite layer and the fiber-reinforced polymeric layer, is a thermo-setting epoxy resin. 9. The method of claim 1, wherein the first portion further includes a second cutout, the second cutout substantially filled by a third portion of metallic material including the second resin. 10. The method of claim 9, wherein the third portion includes a metal selected from a group consisting of alloys of titanium, alloys of aluminum, and alloys of iron. 11. The method of claim 10, wherein the third portion includes an alloys of titanium selected from a group consisting of (Ti-6Al-4V), (Ti-15V-3Cr-3Sn-3Al) and (Ti-15Mo-3Al-3Nb). 12. The method of claim 9, wherein: an adhesive resin is applied between the first portion and the second portion; and an adhesive resin is applied between the first portion and the third portion. 13. The method of claim 11, wherein the first cutout and the second cutout are non-coterminous. 14. A method of forming a laminate structure, comprising: forming a metal-polymer composite layer of substantially uniform thickness, the metal-polymer composite layer including: a first portion of non-metallic material interrupted by the presence of a first cutout; a second portion of metallic material including substantially filling the first cutout of the first portion; and forming a fiber-reinforced polymeric layer, the fiber-reinforced polymeric layer non-interruptedly extending along the metal-polymer composite layer; forming a metal layer, the metal layer extending along a portion of the fiber-reinforced polymeric layer such that the laminate structure is of non-uniform thickness; coupling the fiber-reinforced polymeric layer adjacent to the metal-polymer composite layer; and coupling the metal layer adjacent to the fiber-reinforced polymeric layer. 15. The method of claim 14, wherein the first portion includes a fiber selected from a group consisting of aramids, polyolefins, glass, carbon, boron, and ceramics; and wherein the second portion includes a metal selected from a group consisting of alloys of titanium, alloys of aluminum, and alloys of iron. 16. The method of claim 15, wherein the alloys of titanium are selected from a group consisting of (Ti-6Al-4V), (Ti-15V-3Cr-3Sn-3Al) and (Ti-15Mo-3Al-3Nb). 17. The method of claim 14, wherein the metal-polymer composite layer has non-tapered ends. 18. A method of forming a laminate structure, comprising: forming a region, wherein forming the region includes: forming a first layer that has a first face and a second face spaced apart from the first face, the first layer extending to a terminal edge and includes a first portion having a non-metallic material, the first portion defining at least one cutout region, the first layer further including a second portion of a metallic material formed within the at least one cutout region; forming a second layer adjacent the first layer that non-interruptedly extends along the first layer from the first face to the second face, the second layer extending to the terminal edge and formed of a non-metallic material; and forming a third layer adjacent the second layer that interruptedly extends along a portion of the second layer, the third layer formed of a metallic material. 19. The method of claim 18, wherein the first layer is of substantially uniform thickness. 20. The method of claim 19, wherein the first portion includes a fiber selected from a group consisting of aramids, polyolefins, glass, carbon, boron, and ceramics; and wherein the second portion includes a metal selected from a group consisting of alloys of titanium, alloys of aluminum, and alloys of iron.