Aircraft Composite Lightning Protection With Thermal Bonding
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Solution Overview
Problem
Existing methods for providing lightning strike protection to thermoplastic composite aircraft components are in need of improvement.
Innovation Solution
A method involving the arrangement of a lightning strike protection layer with interconnected conductive elements over a thermoplastic composite structure, followed by heating to bond the layer to the structure using a heated tool or metal conductor, thereby integrating lightning strike protection into the aircraft component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lightning strike protection layer is bonded to a thermoplastic composite structure using conventional methods, then lightning protection is provided, but the bonding strength and structural integrity are insufficient
Solution Approach 1:
The patent applies parameter changes by controlling the temperature and pressure parameters during the bonding process. The tool is heated to a specific temperature range to melt the thermoplastic material, and controlled pressure is applied to ensure proper bonding between the lightning strike protection layer and the composite structure, thereby achieving both reliable lightning protection and strong bonding.
Solution Approach 2:
The patent uses composite materials by combining the lightning strike protection layer (containing conductive elements) with the thermoplastic composite structure through thermal bonding. This creates a multi-layer composite structure that integrates both the protective function of the LSP layer and the structural function of the thermoplastic composite, achieving both lightning protection and structural integrity.
2Strength
If the thermoplastic material is heated to bond the lightning strike protection layer, then bonding is achieved, but the heating process is complex and time-consuming
Solution Approach 1:
The patent uses a heated tool as an intermediary device to transfer thermal energy to the thermoplastic material. The tool acts as a mediator between the heat source and the material, concentrating the heating action at the bonding interface and simplifying the overall heating process while achieving effective bonding.
Solution Approach 2:
The patent applies local quality by concentrating the heating action at specific bonding interfaces rather than heating the entire component uniformly. The heated tool applies localized thermal energy to the thermoplastic material at the bonding zones, reducing the overall heating time and energy consumption while maintaining bonding strength.
3Reliability
If multiple layers are bonded together to provide comprehensive protection, then protection effectiveness is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent merges the lightning strike protection layer with the thermoplastic composite structure into a single integrated component through thermal bonding. This combining of functions (protection and structure) into one unified structure simplifies the manufacturing process compared to assembling separate components, while maintaining comprehensive protection effectiveness.
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 method effectively bonds the lightning strike protection layer to the thermoplastic composite structure, enhancing the component's structural integrity and providing comprehensive lightning protection.
Implementation Method 1
The tool is heated to provide a heated tool. The thermoplastic material is heated using the heated tool to melt the thermoplastic material
Implementation Method 2
The thermoplastic material is heated using the heated tool to melt the thermoplastic material and bond the lightning strike protection layer to the thermoplastic composite structure
Implementation Method 3
The metal conductor is heated to provide a heated metal conductor. The lightning strike protection layer is heated using the heated metal conductor to melt thermoplastic material
Implementation Method 4
The lightning strike protection layer is heated using the heated metal conductor to melt thermoplastic material of the pre-consolidated fiber reinforced thermoplastic structure
Implementation Method 5
The heating device may be configured as or otherwise include an induction heating device and/or a conduction heating device
Data Source
AI summary
A formation method is provided during which a lightning strike protection and thermoplastic material are arranged on a tool. The lightning strike protection includes a plurality of interconnected conductive elements. A thermoplastic composite structure is arranged over the lightning strike protection and the thermoplastic material with the lightning strike protection and the thermoplastic material between the tool and the thermoplastic composite structure. The tool is heated to provide a heated tool. The thermoplastic material is heated using the heated tool to melt the thermoplastic material and bond the lightning strike protection layer to the thermoplastic composite structure.