Composite Edge Dielectric Protection via Mold Resin Accumulation
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Solution Overview
Problem
Current methods for protecting composite aircraft components from electric discharges, especially at edges with complex geometry, are inefficient and costly due to manual application and lack of durability, requiring additional processes that do not adapt well to curved surfaces.
Innovation Solution
Integrating a layer of non-conductive, insulating resin into the manufacturing process of composite materials, using the mould to accommodate resin accumulation at edges, ensuring dielectric protection without subsequent operations, and adjusting resin thickness for optimal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual application of sealing elements or insulating films is used to protect edges, then dielectric protection is achieved, but manufacturing cost increases and durability decreases
Solution Approach 1:
The patent merges the edge protection function with the structural component itself by integrating insulating material directly into the edge geometry during composite manufacturing. This eliminates separate protection layers and manual application processes, achieving both durability through integral construction and ease of manufacture through process integration.
Solution Approach 2:
The edge of the composite component serves multiple functions simultaneously: it provides structural support, defines the component boundary, and delivers dielectric protection. The insulating material integrated into the edge creates a multi-functional element that eliminates the need for separate protection systems.
2Reliability
If insulating material is applied to edges with complex geometry, then dielectric protection is provided, but application difficulty increases and cost rises
Solution Approach 1:
The insulating material is incorporated into the edge structure during the initial composite manufacturing process rather than being applied afterward. The mould is designed with features that ensure proper material distribution and insulation thickness before the component is removed, eliminating difficult post-manufacturing operations.
Solution Approach 2:
The composite manufacturing process itself provides the dielectric protection function. The resin and fibre arrangement during lamination automatically creates the insulating edge structure without requiring separate application operations, tools, or additional manual intervention for complex geometries.
3Reliability
If additional processes are used for edge protection, then dielectric coverage is achieved, but manufacturing time increases
Solution Approach 1:
The patent combines multiple manufacturing operations into a single integrated process. The edge protection is created during the primary composite lamination operation, eliminating sequential steps for edge sealing or insulating and thereby maintaining high manufacturing productivity.
Solution Approach 2:
The composite manufacturing process simultaneously creates the structural component and the protective edge insulation in one operation. This multi-functional approach eliminates the need for separate protection processes and maintains production efficiency.
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
Provides robust, cost-effective, and adaptive dielectric protection for aircraft components, particularly at complex geometries, enhancing safety by preventing electric arcs and ignition risks during lightning strikes.
Implementation Method 1
a layer of non-conductive, insulating resin arranged on the edges that require protection
Data Source
AI summary
Protection of elements (1) of composite material protected at its points of complex geometry, such as various edges and corners, against electric discharges to which they are potentially exposed, said elements (1) being obtained by applying a cycle of temperature and pressure to a composite material arranged in a mold (2) designed in such a way that, once the geometry of the element (1) is known, the mold (2) includes free spaces (6) intended for the accumulation of resin from the process of manufacture of said element (1), and said resin will form the dielectric protection of the various edges or corners of the element (1) as it builds up, forming layers (3) that are disposed around the free edges of the element (1), thus endowing these surfaces of various edges or corners with dielectric protection of electrical insulation that prevents possible discharges and expulsion of hot particles in the case of electric discharge on said element (1). The invention also relates to a process of manufacture of an element (1) of composite material as such.