Extendible Composite Mast With Embedded Conductors for Coilable Deployment
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Solution Overview
Problem
Existing extendible masts face challenges in efficiently transmitting signals and power to equipment, particularly for complex electronic devices, due to interference and damage risks from electrical transmission elements during extension and retraction, and require solutions that are practical for manufacturing and deployment.
Innovation Solution
An extendible mast with integrated electrical conductors positioned between fibre reinforced layers, near the neutral axis, and with cut-out portions to accommodate the conductors, allowing for strain reduction and maintaining structural integrity, enabling easy deployment and storage while maintaining electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical transmission elements are attached to the mast surface, then electrical connectivity is provided, but the elements interfere with the coiling mechanism and increase risk of damage
Solution Approach 1:
The electrical conductors are merged with the mast structure by integrating them between fibre reinforced layers during manufacturing. This creates a unified composite structure where the conductors become an intrinsic part of the mast, eliminating the need for separate attachment and preventing interference with the coiling mechanism.
Solution Approach 2:
The electrical conductors are nested within the laminate structure of the mast, positioned between fibre reinforced layers. This nesting approach protects the conductors within the mast's composite structure while maintaining electrical connectivity, and allows the entire assembly to coil together without external elements interfering.
2Ease of operation
If electrical cables are placed outboard of the mast, then coiling is facilitated, but bulk interferes with compact coil formation
Solution Approach 1:
The conductors are merged into the mast's composite structure, eliminating separate cable management. The integrated conductors coil with the mast itself, achieving compact storage without requiring additional space for external cable routing.
3Reliability
If conductors are integrated between fibre layers, then strain on conductors is reduced, but manufacturing complexity increases
Solution Approach 1:
The mast is constructed as a composite material structure with electrical conductors embedded between fibre reinforced layers during the laminating process. This composite approach integrates multiple functions (structural strength and electrical conductivity) into a single manufactured component, reducing strain on conductors while using established composite manufacturing techniques.
4Reliability
If multiple transmission elements are embedded, then electrical services are improved, but deployment time increases
Solution Approach 1:
Multiple transmission elements are merged into the mast structure during manufacturing, with conductors positioned between fibre layers. This integration means all electrical connections are pre-established within the mast itself, eliminating time-consuming field installation of separate cables and enabling rapid deployment.
Data Source
AI summary
An extendible mast (1) for deploying equipment comprises a composite member formed from plural fibre reinforced layers (75) laminated together in a matrix material in the form of a shell that is constructed and arranged so as to be configurable between a coiled form and an extended form. When extended the member is resiliently biased in the form of an elongate tube having a slit along its length formed by longitudinal edges of the member. One or more electrical conductors (50) extend along at least part of the longitudinal extent of the member for making connection to the equipment. The conductors are integrated between two or more layers within the laminate.