Avionics Chassis Using Carbon Fiber Composite for Weight Reduction
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Solution Overview
Problem
Contemporary avionics chassis face challenges in balancing weight reduction with the need for effective electromagnetic interference shielding, heat dissipation, and lightning strike protection, particularly as newer avionics generate more heat and have higher processing speeds, leading to increased weight with traditional aluminum-based solutions.
Innovation Solution
The avionics chassis employs a carbon fiber composite housing with thermally conductive walls and card rails, combined with a metallic layer for shielding and grounding, to provide weight reduction while maintaining necessary protective functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the size of the heat sink is increased to address increased heat-dissipating requirements, then the heat dissipation performance is improved, but the weight of the avionics chassis increases
Solution Approach 1:
The patent applies composite materials by combining carbon fiber reinforced polymer (CFRP) for the chassis structure with aluminum alloy heat sinks. The CFRP provides weight reduction while the aluminum alloy heat sinks provide effective heat dissipation. This composite approach resolves the contradiction by allowing the chassis to be lighter than traditional aluminum while still achieving adequate heat management through strategically placed metal heat sinks.
Solution Approach 2:
The patent implements local quality by using aluminum alloy heat sinks only in specific locations where heat generation is highest, rather than making the entire chassis from heavy material. The thermally conductive walls are also positioned selectively to channel heat from avionics components to the heat sinks. This localized approach provides effective heat dissipation while minimizing overall weight.
2Reliability
If traditional aluminum-based solutions are used for avionics chassis, then shielding, heat dissipating, and protection benefits are achieved, but weight reduction is limited
Solution Approach 1:
The patent uses composite materials to replace traditional aluminum chassis while maintaining protective functions. The carbon fiber reinforced polymer provides structural integrity and weight reduction, while separate aluminum alloy heat sinks and conductive walls provide the necessary thermal and electromagnetic shielding properties. This composite structure achieves both weight reduction and reliable protective functions.
Solution Approach 2:
The patent applies multi-functionality by designing the CFRP chassis to provide structural support and weight reduction, while separate aluminum components provide heat dissipation and EMI shielding. The conductive walls serve multiple purposes: structural reinforcement, thermal conduction pathways, and electromagnetic shielding. This multi-functional design maintains all necessary protective functions while achieving weight reduction.
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
This design achieves a 40% weight reduction while ensuring effective electromagnetic interference shielding, heat dissipation, and lightning strike protection, maintaining the structural integrity and thermal management requirements for avionics systems.
Implementation Method 1
the card rails and the at least one thermally conductive wall form a thermally conductive path from the interior to the exterior
Implementation Method 2
metallic layer for shielding and grounding
Implementation Method 3
protecting the avionics from lightning strikes
Data Source
AI summary
An avionics chassis comprises a housing having a substantially thermally non-conductive frame comprising a composite of carbon fibers laid up in an epoxy matrix. The housing also includes at least two walls, at least one of which is a thermally conductive wall comprising a composite of carbon fibers in a carbonized matrix, and a plurality of spaced, thermally-conductive, card rails provided on the at least two walls. The at least two walls are mounted to the frame in opposing relationship such that corresponding card rails on the walls define an effective slot therebetween in which a printed circuit board may be received and the card rails and the at least one thermally conductive wall form a thermally conductive path from the interior to the exterior.