Fiber Composite Structural Component with Conductive Metal Profile
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Solution Overview
Problem
Current fiber composite materials used in aircraft structures lack reliable electrical conductivity, leading to inadequate lightning protection, electromagnetic radiation screening, and increased structural weight and complexity in production and assembly, with potential mechanical damage during production.
Innovation Solution
Integration of an electrically conductive metal profile on the outer surface of fiber composite materials, which provides improved electrical conductivity and mechanical protection, along with an optional insulating compensation layer to reduce impact loads and thermal stresses, forming a network for electromagnetic screening and simplified electrical system architecture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional metallic components are added to ensure electrical functions, then electrical conductivity and lightning protection are improved, but structural weight and production complexity increase
Solution Approach 1:
The patent combines the metallic profile with the fiber composite structure by integrating it during the manufacturing process. The metallic profile is positioned within a mold and the fiber composite material is cured around it, creating a unified structure where the metal profile becomes an integral part of the component rather than a separate addition, thereby reducing production complexity
Solution Approach 2:
The metallic profile serves multiple functions simultaneously: it provides electrical conductivity for lightning protection and electromagnetic shielding, acts as a structural reinforcement element, and serves as an attachment point for fasteners. This multi-functionality eliminates the need for separate components for each function, reducing overall structural weight and production complexity
2Reliability
If additional metallic components are added to ensure electrical functions, then electrical conductivity and lightning protection are improved, but structural weight increases
Solution Approach 1:
The metallic profile serves multiple functions simultaneously: it provides electrical conductivity for lightning protection and electromagnetic shielding, acts as a structural reinforcement element, and serves as an attachment point for fasteners. This multi-functionality eliminates the need for separate components for each function, reducing overall structural weight
Solution Approach 2:
The patent creates a composite structure combining fiber composite material with a metallic profile. The fiber composite provides lightweight structural strength while the metallic profile provides electrical conductivity. This composite approach achieves multiple functions with optimized weight compared to using solid metallic structures for all functions
3Strength
If fiber composite components are made stronger to prevent damage, then mechanical strength is improved, but detection of hidden damage becomes more difficult
Solution Approach 1:
The patent applies a color-changing indicator system where the fiber composite material changes color when damage occurs. This visual indicator allows easy detection of mechanical damage such as delamination or fiber breakage, enabling timely maintenance while maintaining the strength benefits of fiber composite construction
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
The solution enables reduced production and assembly complexity, weight reduction, and enhanced mechanical and electrical functionality, while minimizing the risk of structural damage and electromagnetic interference, thus optimizing the use of fiber composite materials.
Implementation Method 1
The metal profile is arranged on an outer surface of the structural component and in addition to the electrical conductivity provides component protection
Implementation Method 2
an insulating compensation layer which has a lower modulus of elasticity than the metal profile... the insulating compensation layer absorbs impact loads and reduces thermal stresses
Data Source
AI summary
A structural component includes a fiber composite material structure having an outer surface and an electrically conductive metal profile disposed on the outer surface of the fiber composite material structure. The metal profile provides provide improved electrical conductivity of the structural component and component protection.