Composite Fastening Structure for Lightning Current Distribution

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Solution Overview

Problem

Existing fastening structures in composite materials, such as those used in aircraft, face challenges in preventing current concentration at fasteners during lightning strikes or other current-generating situations, leading to spark generation due to difficulties in current flow between layers.

Innovation Solution

A fastening structure comprising a first structural member with an electrically-conductive inner layer and a non-conductive outer layer, and a second structural member with an electrically-conductive surface in contact with the first, allowing a metallic fastener to penetrate both surfaces, facilitating current flow within the conductive layers and reducing concentration at the fastener.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a fastener is used to join composite structural members, then mechanical fastening is achieved, but current concentration occurs at the fastener leading to spark generation

Engineering Contradiction:
Improvefastening strengthVSAvoidcurrent concentration and spark generation
Core Design Contradiction:
StrengthVSObject-affected harmful factors

Solution Approach 1:

An electrically conductive member is introduced as an intermediary element between the fastener and the composite structural members. This conductive member serves as a mediator that provides a dedicated low-resistance path for electrical current, preventing current concentration at the fastener while maintaining the mechanical fastening function. The conductive member is positioned to contact both structural members and the fastener, creating a separate current flow path.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The electrical conduction function is segmented from the mechanical fastening function. Instead of relying on the fastener alone to handle both mechanical load and electrical current, the solution divides these functions by introducing a separate conductive member specifically for current conduction. This segmentation allows each component to optimize its primary function without compromising the other.

Inventive Principle:
Principle #1Segmentation

2Use of energy by moving object

If current flows across composite structural members during lightning strike, then electrical energy is transmitted, but current concentrates at the fastener causing harmful effects

Engineering Contradiction:
Improvecurrent flowVSAvoidcurrent concentration and spark generation
Core Design Contradiction:
Use of energy by moving objectVSObject-generated harmful factors

Solution Approach 1:

The electrically conductive member acts as an intermediary that intercepts and redirects electrical current away from the fastener. By providing an alternative conduction path through the conductive member that contacts both structural members, the system prevents current from concentrating at the fastener during lightning strikes or other high-current events.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The solution converts the potentially harmful current concentration effect into a beneficial distributed flow pattern. By introducing the conductive member, the harmful concentration of current at the fastener is transformed into a distributed current flow through the conductive member and into the structural members, eliminating sparks while maintaining electrical conductivity.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

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

Effectively suppresses spark generation by allowing current to flow within the conductive layers, reducing concentration at the fastener and enhancing safety in applications like aircraft.

Implementation Method 1

a first electrically-conductive surface that has electric conductivity; a second electrically-conductive surface in contact with the first electrically-conductive surface and having electric conductivity

Methodology Applied
Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentEP3511579B1Fastening structure
Publication Date: 2021.01.27 SUBARU CORP
  • EP3511579B1 patent drawingFigure 1~2
  • EP3511579B1 patent drawingFigure 3A~4

AI summary

A fastening structure (1) includes a first structural member (20), a second structural member (30), and a fastening member (40). The first structural member (20) includes a composite material, and has a first electrically-conductive surface (21a) having electric conductivity. The second structural member (30) has a second electrically-conductive surface (31a). The second electrically-conductive surface (31a) is in contact with the first electrically-conductive surface (21a) and has electric conductivity. The fastening member (40) penetrates the first electrically-conductive surface (21a) and the second electrically-conductive surface (31a), and fastens the first structural member (20) and the second structural member (30).