Braided Composite Yarns Integrated Electrical Networks
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Solution Overview
Problem
Current composite materials lack integrated electrical data and power networks, limiting their functionality and efficiency in structural applications.
Innovation Solution
The integration of braided composite yarns with conductive wires and structural yarns to form triaxial braided fabrics, which are embedded within composite materials like carbon fiber prepregs, enabling the creation of robust electrical networks within the material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If composite materials are used for structural applications, then mechanical strength and durability are improved, but integrated electrical data and power networks are lacking
Solution Approach 1:
The patent combines structural composite materials with electrical network components by integrating braided composite yarns containing conductive wires directly into the composite material structure. This merging allows the material to simultaneously provide mechanical support and electrical connectivity, eliminating the need for separate electrical installations.
Solution Approach 2:
The invention uses composite-integrated electrical networks where braided composite yarns are embedded within composite materials. These yarns contain multiple conductors insulated with different materials, creating a multi-functional composite structure that provides both structural integrity and electrical functionality.
2Adaptability or versatility
If electrical networks are added to composite materials, then electrical functionality is improved, but mass and volume efficiency deteriorate
Solution Approach 1:
The braided composite yarns serve multiple functions simultaneously: they provide structural reinforcement to the composite material while also carrying electrical conductors for power and data transmission. This multi-functionality eliminates the need for separate structural and electrical components, reducing overall mass.
Solution Approach 2:
The electrical conductors are nested within the braided composite yarns, which are themselves embedded within the composite material structure. This nested arrangement allows electrical networks to be housed within the existing structural framework, minimizing additional volume and weight.
3Adaptability or versatility
If braided composite yarns are embedded within composite materials, then electrical connectivity is improved, but manufacturing complexity increases
Solution Approach 1:
The braided composite yarns with integrated conductors are prepared and pre-positioned before the final composite material formation. This preliminary action allows the electrical network structure to be established in advance, simplifying the subsequent embedding process and ensuring proper conductor placement.
Solution Approach 2:
The braided composite yarns act as intermediaries between the structural composite material and the electrical conductors. These yarns provide a convenient medium for integrating conductors into the composite structure, facilitating manufacturing by decoupling the structural and electrical integration processes.
4Power
If conductive wires are integrated into braided yarns, then current carrying capacity is improved, but thermal management challenges increase
Solution Approach 1:
Different insulation materials with varying thermal properties are used for different conductors within the braided yarns. This local differentiation allows optimization of thermal management for specific high-current conductors while maintaining electrical insulation, enabling better heat dissipation where needed.
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 solution allows for mass and volume-efficient functional structural systems with reliable electrical connectivity, enhanced thermal management, and increased current carrying capacity, while maintaining mechanical integrity and surface finish.
Implementation Method 1
The braided composite yarn preferably comprises one or more multicomponent fiber bundles... At least one conductive wire wrapped around an axial yarn of the braided composite yarn... At least some of the conductive wire is preferably soldered to at least one of the conductors
Implementation Method 2
At least some of the conductive wire is preferably soldered to at least one of the conductors in the axial yarn
Implementation Method 3
enhanced thermal management... while maintaining mechanical integrity and surface finish
Data Source
AI summary
A composite material comprising braided composite yarns that can be embedded within or at the surface of the material. The braided composite yarns can incorporate one or more multicomponent fiber bundles. The braided composite yarns can be the axial yarns in a triaxial braided fabric that has structural yarns as the bias yarns. The composite material can comprise a carbon fiber prepreg. The thickness of each braided composite yarn can be approximately the thickness of a single composite ply. At least one conductive wire can be wrapped around an axial yarn of the braided composite yarn at a location desirable for electrical contact to be made to at least one conductor in the axial yarn. At least some of the conductive wire is preferably soldered to at least one of the conductors. The conductive wire can be twisted with a structural yarn and is stitched across the braided composite yarn. A conductive pad can be soldered to the one conductive wire.