Method and apparatus for forming a composite structural element
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Solution Overview
Problem
Composite materials used in aircraft structures provide less electromagnetic shielding than metallic materials, leading to reduced current dissipation during electromagnetic events like lightning strikes, which can compromise structural integrity.
Innovation Solution
Incorporating an interwoven wire fabric (IWWF) as a conductive laminate over composite structures to create an optimal conductive pathway, designed using computational models to simulate and analyze current flow, ensuring the risk to structural integrity is below a threshold.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used in aircraft structures, then weight is reduced and strength-to-weight ratio is improved, but electromagnetic shielding capability deteriorates
Solution Approach 1:
The invention uses a hybrid composite structure combining non-conductive composite materials (for weight reduction) with conductive interwoven wire fabric (for electromagnetic shielding). This creates a multi-material composite that simultaneously achieves lightweight properties and lightning strike protection, resolving the contradiction between weight reduction and electromagnetic shielding capability
Solution Approach 2:
The conductive interwoven wire fabric is strategically integrated into specific regions of the composite structure where electromagnetic shielding is most critical, such as areas prone to lightning strikes or near sensitive electrical systems. This localized application provides targeted protection while minimizing overall weight penalty
2Weight of moving object
If composite materials are used in aircraft structures, then weight is reduced, but current dissipation capability deteriorates
Solution Approach 1:
The conductive interwoven wire fabric acts as an intermediary layer within the composite structure, providing a dedicated pathway for current dissipation. This intermediary conductive network enables effective current channeling while allowing the bulk composite material to maintain its lightweight properties
3Reliability
If interwoven wire fabric is added to composite structures, then electromagnetic shielding capability is improved, but device complexity increases
Solution Approach 1:
The conductive interwoven wire fabric is merged with the composite structure during the manufacturing process, integrating the electromagnetic shielding function into the structural component itself. This consolidation eliminates the need for separate shielding layers or additional assembly steps, reducing overall system complexity despite adding functional capability
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 IWWF effectively channels electromagnetic currents, minimizing arcing and structural damage from lightning strikes, thereby maintaining the integrity of composite aircraft structures.
Implementation Method 1
the candidate interwoven wire fabric is arranged to form an optimal conductive pathway in the structural element
Data Source
AI summary
A method and system for designing a structural element for an aircraft includes defining a structural element, the structural element including a composite structure and a candidate interwoven wire fabric, wherein the candidate interwoven wire fabric forms a conductive pathway in the structural element. This may include generating a computer model of the composite structure; generating a computer model of the candidate interwoven wire fabric; forming a virtual prototype of the structural element including the composite structure and candidate interwoven wire fabric integrated therein; simulating, via a finite element model, a direct current injection event into the virtual prototype; determining an expected conductive pathway; identifying a risk associated with the expected conductive pathway in the virtual prototype; and implementing, as the structural element, the composite structure and the candidate interwoven wire fabric when the risk is less than a threshold risk.