Composite Panel with Integrated Circuit for Aircraft Weight Reduction
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Solution Overview
Problem
Aircraft weight is significantly contributed to by complex electrical systems, which also increase manufacturing time and costs due to the need for extensive wiring harnesses, limiting the potential for weight reduction using conventional materials.
Innovation Solution
A composite panel with integrated electrical circuits is developed, featuring a matrix-permeable reinforced material assembly and electrical circuits on a film substrate with holes for reduced surface area, allowing for the integration of electrical devices and improved adhesion, thereby reducing weight and installation complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional wiring harnesses are used for electrical systems in aircraft, then electrical connectivity is achieved, but aircraft weight increases significantly
Solution Approach 1:
The patent combines the electrical circuit board with the composite panel structure, integrating the electrical system directly into the panel rather than using separate wiring harnesses. This merging eliminates the need for additional wiring components and reduces overall aircraft weight while maintaining electrical connectivity functionality
Solution Approach 2:
The composite panel serves multiple functions: it provides structural support as a panel while simultaneously housing electrical circuits and providing electrical connectivity. This multi-functionality eliminates the need for separate wiring harnesses and reduces the number of components required, directly addressing the weight reduction goal
2Ease of manufacture
If extensive wiring harnesses are installed behind cabin interior panels, then electrical equipment is connected, but manufacturing time and costs increase
Solution Approach 1:
The electrical circuits are pre-integrated into the composite panel during manufacturing, rather than being installed separately afterward. This preliminary integration of electrical systems into the panel structure eliminates subsequent installation steps and reduces manufacturing time and costs
Solution Approach 2:
By merging the electrical circuit board with the composite panel into a single integrated component, the patent eliminates the need for separate installation of wiring harnesses, thereby reducing manufacturing complexity and installation time
3Weight of moving object
If electrical circuits are integrated into composite panels, then weight is reduced, but adhesion and delamination risks become concerns
Solution Approach 1:
The patent uses a porous matrix material in the composite panel that allows for mechanical interlocking with the electrical circuit board. The porosity enables the matrix to penetrate and bond with the circuit board, creating strong adhesion and preventing delamination while maintaining the weight reduction benefits of integration
Solution Approach 2:
The patent employs composite materials with specific adhesion properties to ensure reliable bonding between the electrical circuit board and the panel structure. The composite material system is designed to provide both structural integrity and strong interfacial adhesion, addressing reliability concerns
Data Source
AI summary
Here are described composite panels comprising at least one integrated or embedded electrical circuit, their methods of manufacturing and their use in the aeronautic and aircraft industries. Also described are aircraft components including the composite panel as defined herein.