Multi-functional layer for stop etch in laser coating removal

Patent metadata

Field	Value
Publication number	US-12036623-B2
Application number	US-202117498270-A
Country	US
Kind code	B2
Filing date	Oct 11, 2021
Priority date	Oct 11, 2021
Publication date	Jul 16, 2024
Grant date	Jul 16, 2024

Abstract

An aircraft skin coating assembly for an aircraft. The coating assembly includes a primer layer deposited on the aircraft skin, an optical stop-etch layer deposited on the primer layer that is reflective at a predetermined wavelength, a coating stack-up deposited on the optical etch-stop layer that provides performance features for the aircraft, and a sealant layer deposited on the stack-up. When a laser coating removal process employing a laser beam is used to remove the coating stack-up for replacement, the stop-etch layer reflects the laser beam to prevent it from penetrating and possibly damaging the aircraft skin.

First claim

What is claimed is:

1. An aircraft skin coating assembly for an aircraft, said coating assembly comprising:
a primer layer deposited on the aircraft skin;
an optical stop-etch layer deposited on the primer layer, said stop-etch layer being optically reflective at a predetermined wavelength, wherein the optical stop-etch layer is a reactive metallic ink and is about 2.5 μm thick;
a coating stack-up deposited on the optical stop-etch layer, said coating stack-up including a plurality of layers each providing a different function from at least one other layer in the stack-up and providing performance features for the aircraft; and
a sealant layer deposited on the stack-up, wherein the optical stop-etch layer operates and is configured to reflect a laser beam that is being used to remove the coating stack-up in a laser coating removal process, and wherein the reactive metallic ink and the 2.5 μm thickness of the optical stop-etch layer are effective to prevent the laser beam from penetrating the primer layer and heating the aircraft skin.

2. The assembly according to claim 1 wherein the optical stop-etch layer is 90% reflective at the predetermined wavelength.

3. The assembly according to claim 1 wherein the aircraft is a military aircraft.

4. The assembly according to claim 1 wherein the optical stop-etch layer is deposited on the primer layer by aerosol jet, inkjet, screen printing or spray coating.

5. An aircraft skin coating assembly for an aircraft, said coating assembly comprising:
a reactive metallic ink stop-etch layer deposited on the aircraft skin to a thickness of about 2.5 μm; and
a coating stack-up deposited on the stop-etch layer, said coating stack-up including a plurality of layers each providing a different function from at least one other layer in the stack-up and providing performance features for the aircraft and said stop-etch layer operates and is configured to a reflect a laser beam that is used to remove the coating stack-up in a laser coating removal process to remove the coating stack-up, and wherein the reactive metallic ink and the 2.5 μm thickness of the optical stop-etch layer are effective to prevent the laser beam from heating the aircraft skin.

6. The assembly according to claim 5 further comprising a primer layer deposited on the aircraft skin between the skin and the stop-etch layer.

7. The assembly according to claim 5 further comprising a sealant layer deposited on the stack-up.

8. The assembly according to claim 5 wherein the stop-etch layer is 90% reflective at the predetermined wavelength.

9. The assembly according to claim 5 wherein the aircraft is a military aircraft.

10. The assembly according to claim 5 wherein the optical stop-etch layer is deposited by aerosol jet, inkjet, screen printing or spray coating.

11. A method for fabricating a coating assembly on an aircraft skin, said method comprising:
depositing a primer layer on the aircraft skin;
depositing an optical stop-etch layer on the primer layer, said stop-etch layer being optically reflective at a predetermined wavelength, wherein depositing an optical stop-etch layer includes depositing a reactive metallic ink to be about 2.5 μm thick;
depositing a coating stack-up on the optical stop-etch layer, said coating stack-up including a plurality of layers each providing a different function from at least one other layer in the stack-up and providing performance features for the aircraft, wherein the optical stop-etch layer operates and is configured to a reflect a laser beam that is being used to remove the coating stack-up in a laser coating removal process, and wherein the reactive metallic ink and the 2.5 μm thickness of the optical stop-etch layer are effective to prevent the laser beam from penetrating the primer layer and heating the aircraft skin; and
depositing a sealant layer on the stack-up.

12. The method according to claim 11 wherein depositing the optical stop-etch layer causes the ink to chemically react with the primer layer to become a conductive metal layer.

13. The method according to claim 12 wherein the ink is formulated to produce a solid silver layer on the primer layer.

14. A method for removing a coating stack-up that is part of a coating assembly on an aircraft skin, said coating stack-up including a plurality of layers each providing a different function than at least one other layer in the stack-up and providing performance features for the aircraft, said coating assembly further including a primer layer on the aircraft skin and an optical stop-etch layer on the primer layer, said stop-etch layer being a reactive metallic ink about 2.5 μm thick and being optically reflective at a predetermined wavelength, said coating stack-up being on the stop-etch layer, said method comprising directing a laser beam into the coating stack-up that is reflected off of the optical stop-etch layer and removes the coating stack-up, wherein the reactive metallic ink and the 2.5 μm thickness of the optical stop-etch layer are effective to prevent the laser beam from penetrating the primer layer and heating the aircraft skin.

Assignees

• Northrop Grumman Systems Corp

Inventors

• Knight Mark W
• Shindo Patrick W
• Limburg Connor
• Tice Jesse

Classifications

• B64F5/40 Primary

  Maintaining or repairing aircraft · CPC title

• B64C1/12

  Construction or attachment of skin panels · CPC title

• B23K26/362

  Laser etching · CPC title

• B05D7/5883

  No curing step for any layer · CPC title

• B05D5/067

  Metallic effect · CPC title