Laminate of metal sheets and polymer

Abstract

The invention relates to a laminate of metal sheets and fiber-reinforced polymer layers connected thereto. The laminate comprises at least one thick metal sheet with a thickness of at least 1 mm that is connected to the rest of the laminate by means of at least one fiber-reinforced polymer layer, the fiber volume content of which is at most 45 volume-%. The invention also relates to a method for producing the laminate as well as skin sheets reinforced with the laminate for an aircraft or spacecraft.

1 . A structure comprising:
 at least a first metal layer having a constant thickness of at least about 1.5 mm; and   at least a second metal layer having a constant thickness of at least about 1.5 mm,   wherein the first metal layer and the second metal layer are connected to each other by a fiber-reinforced epoxy prepreg having a fiber volume content not exceeding about 39%.   
     
     
         2 . The structure of  claim 1  wherein the fiber-reinforced epoxy prepreg includes reinforcing fibers embedded in a polymer matrix. 
     
     
         3 . The structure of  claim 2  wherein the reinforcing fibers are selected from the group consisting of glass fibers, carbon fibers, metal fibers, drawn thermoplastic fibers, natural fibers and combinations thereof. 
     
     
         4 . The structure of  claim 2  wherein the polymer matrix is a thermoplastic polymer matrix or a thermosetting polymer matrix. 
     
     
         5 . The structure of  claim 1  wherein the thickness of the first metal layer and the second metal layer is about 2.5 mm. 
     
     
         6 . The structure of  claim 2  wherein the reinforcing fibers are impregnated with the polymer matrix in a partially cured state. 
     
     
         7 . The structure of  claim 2  wherein the reinforcing fibers are substantially continuous and extend in one direction. 
     
     
         8 . The structure of  claim 2  wherein the reinforcing fibers are present in two groups that are substantially continuous and extend in parallel, each group making an identical angle with an intermediary direction. 
     
     
         9 . The structure of  claim 1  wherein the first metal layer and the second metal layer include an aluminum alloy. 
     
     
         10 . The structure of  claim 1  wherein the first metal layer and the second metal layer include an aluminum-lithium alloy. 
     
     
         11 . The structure of  claim 1  wherein the first metal layer and the second metal layer include an aluminum-magnesium-scandium alloy.