Aircraft Electrical Fasteners for Composite Skin Bonding
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Solution Overview
Problem
Composite materials in aircraft construction exhibit high electrical resistance, limiting effective bonding and grounding, necessitating additional weight and time-consuming manual installation of metallic strips and sealants, which are not functional beyond fixation.
Innovation Solution
An aircraft electrical connection system using metallic fastening elements to directly transfer electrical currents from metallic elements to composite skins, eliminating the need for metallic strips and enabling continuous current flow without wires, reducing weight and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic strips are fastened to composite material using traditional fasteners, then electrical connectivity is achieved, but weight increases and installation time increases
Solution Approach 1:
The fastening element combines mechanical fastening function with electrical conductivity function in a single component. The metallic fastening element directly transfers electrical currents from metallic elements to composite skins without requiring separate metallic strips and fasteners, thereby reducing weight while maintaining electrical connectivity.
Solution Approach 2:
The fastening element serves multiple functions simultaneously: mechanical attachment, electrical current transfer, and structural bonding. This multi-functionality eliminates the need for additional dedicated electrical connection components, reducing overall weight and simplifying the system.
2Reliability
If metallic strips are installed with traditional fasteners and sealants, then electrical connectivity is achieved, but installation time increases
Solution Approach 1:
The fastening element integrates electrical connection functionality into the mechanical fastening process itself. Electrical currents are transferred directly through the metallic fastening elements during standard assembly operations, eliminating the need for separate installation steps for metallic strips and sealants, thereby reducing installation time.
Solution Approach 2:
The fastening element automatically provides electrical connectivity as part of its mechanical function. The electrical current transfer occurs inherent in the fastening process itself without requiring additional manual operations for sealing or separate electrical connection installation.
3Weight of moving object
If composite materials are used in aircraft construction, then strength to weight ratio improves, but electrical conductivity deteriorates
Solution Approach 1:
The metallic fastening elements act as intermediary conductive pathways between metallic structural elements and composite skin. These fasteners provide the necessary electrical conductivity bridge, allowing current flow through the composite material interface without requiring the composite material itself to be conductive.
Solution Approach 2:
Electrical conductivity is provided locally at the critical interfaces where metallic and composite materials meet. The metallic fastening elements create concentrated conductive pathways at these interfaces, providing sufficient electrical connectivity without requiring the entire composite structure to have enhanced conductivity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively transfers significant electrical currents through composite materials, reducing aircraft weight and installation time while maintaining safety and functionality, without the need for additional metallic components or sealants.
Implementation Method 1
the metallic fastening means being configured to transfer electrical currents from the metallic element to the composite skin
Data Source
Figure 1
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Figure 4
AI summary
Aircraft electrical connection system comprising: - a portion of a metallic element (1) of the aircraft, - a portion of a composite skin (2) of the aircraft located adjacent to the portion of the metallic element (1), - a plurality of metallic fastening means (3) joining the composite skin (2) to the metallic element (1), the metallic fastening means (3) being configured to transfer electrical currents from the metallic element (1) to the composite skin (2).