Composite Structure Conductive Layer Masking
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Solution Overview
Problem
Existing methods for manufacturing composite structures with electromagnetic shielding, such as those for aircraft, face challenges in optimizing the electrical connection area, leading to potential damage of conductive layers and increased electrical resistance.
Innovation Solution
A method involving the use of a mask with cavities is employed to integrate an electrically conductive metal member into a composite structure, allowing resin flow and optimizing layer cohesion, thereby minimizing damage and ensuring clean electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual sanding is used to expose the copper grid for electrical connections, then the copper grid can be exposed, but the risk of damaging the copper grid increases and the process requires considerable skill
Solution Approach 1:
The patent applies preliminary action by pre-defining the exposure zones of the copper grid through masks before final assembly. The masks are positioned on the metal part to predetermined positions, and the upper sub-assembly is placed with openings that align with these masked zones, automatically exposing the copper grid without requiring manual sanding operations that could damage the grid.
2Ease of manufacture
If copper patches are bonded to the copper grid to create connection points, then electrical connections can be made, but the electrical resistance of the interface increases
Solution Approach 1:
The patent extracts the unnecessary intermediate copper patches from the connection process. Instead of bonding copper patches to the copper grid, the upper sub-assembly is directly positioned with its openings aligned to expose the copper grid at predetermined connection points, eliminating the additional interface layer that would increase electrical resistance.
3Productivity
If mechanical stripping tools are used to remove the upper sub-assembly, then the copper grid can be exposed, but the process requires considerable skill and time
Solution Approach 1:
The patent applies preliminary action by pre-defining the exposure zones of the copper grid through masks before final assembly. The masks are positioned on the metal part to predetermined positions, and the upper sub-assembly is placed with openings that align with these masked zones, automatically exposing the copper grid without requiring manual sanding operations that could damage the grid.
4Ease of manufacture
If the upper sub-assembly is placed directly on the metal part without masks, then assembly is simpler, but the electrical connection areas cannot be precisely controlled
Solution Approach 1:
The patent introduces masks as intermediary elements between the metal part and the upper sub-assembly. The masks are positioned on the metal part to predetermined positions and define the exact areas where the upper sub-assembly should be placed. This intermediary ensures precise positioning of electrical connections while maintaining a relatively simple assembly process.
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 approach reduces the risk of damaging the metal member, simplifies the preparation of metallized surfaces, and enhances reproducibility by eliminating the need for manual sanding and minimizing electrical resistance.
Implementation Method 1
placement of the upper subassembly at least against a part of the upper face of the metal part not covered by said at least one mask
Data Source
Figure 1~5
AI summary
The present invention relates to a method for manufacturing a composite structure (1) comprising a lower subassembly (10) and an upper subassembly (20) and an electrically conductive layer (30) provided with a metallic element (31). The method includes a step of arranging said metallic element (31) on the lower subassembly (10), a step of placing at least one mask (40) comprising at least one cavity (45) on at least one electrical connection zone (35) of said metallic element, and a step of placing at least the upper subassembly (20) against the upper face (42) of the metallic element (31).