Composite Panel Lightning Protection via Automated Strip Deposition
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Solution Overview
Problem
Current methods for manufacturing composite material panels with lightning strike protection struggle to ensure electrical continuity and effective protection on curved surfaces, as existing automated systems either fail to maintain continuity after deformation or provide inadequate conduction ratios between directions.
Innovation Solution
A method involving the automated deposition of conductive strips with widths less than 20 mm, arranged in parallel series along different directions to form patterns such as parallelograms or diamonds, using an AFP-type fiber placement machine, ensuring electrical conduction in all directions and accommodating curved surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If automated fiber placement machine is used to deposit strips on curved surfaces, then productivity and automation are improved, but strip width is limited to less than 2 inches and electrical conductivity becomes anisotropic
Solution Approach 1:
The patent transitions from single-direction strip deposition to multi-directional deposition pattern. By depositing strips in both longitudinal and transverse directions (creating orthogonal or angled patterns), the solution ensures electrical conductivity in all directions on the curved surface, eliminating the anisotropic conductivity problem while maintaining automation benefits
Solution Approach 2:
The patent divides the lightning protection system into multiple narrow strip segments (each less than 2 inches wide) that are deposited in systematic patterns. These segmented strips work collectively to provide omnidirectional conductivity, with each strip contributing to the overall conductive network in its specific orientation
2Reliability
If manual overlapping of wide lightning protection strips is used, then electrical continuity is ensured, but productivity remains low and manual operation is required
Solution Approach 1:
The patent replaces the manual mechanical overlapping process with an automated deposition system. The AFP machine automatically positions and deposits narrow strips in overlapping patterns, eliminating manual labor while maintaining the electrical continuity function through precise automated control of strip placement and overlap
3Weight of moving object
If CFRP material is used for fuselage panels, then mass is reduced, but electrical conductivity for lightning protection is insufficient
Solution Approach 1:
The patent creates a composite lightning protection system by combining narrow conductive strips with the CFRP panel substrate. The strips (made of conductive materials like metal or conductive polymer) are deposited onto the lightweight CFRP surface, forming a hybrid structure that maintains the weight advantages of composite materials while adding the necessary electrical conductivity for lightning protection
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 guarantees electrical conduction in all directions, meeting aeronautical regulations, while maintaining a balance between protection effectiveness and mass, thus enhancing the reliability of composite material panels against lightning strikes.
Implementation Method 1
the strips having a width of less than 20 mm and being distributed into a first series of parallel strips deposited along a first deposit direction and a second series of parallel strips deposited along a second deposit direction intersecting the first deposit direction
Data Source
Figure 1A~3E
Figure 4A~7
AI summary
The invention relates to a method for manufacturing a composite material panel incorporating lightning protection, comprising strips with a conductive layer. The method is characterized in that it includes an automated step of depositing said strips, said strips (30, 30') having a width of less than 20 mm and being arranged in a first series of parallel strips (30) deposited in a first direction of deposition, and a second series of parallel strips (30') deposited in a second direction of deposition intersecting the first direction of deposition. The invention also relates to a composite material panel manufactured according to this method.