Conducting Installation Element for Composite Aircraft Structures
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Solution Overview
Problem
Aeronautical structures made from composite materials are vulnerable to electrical discharges due to their low conductivity, which can cause damage to both the composite structure and metallic components or equipment, as existing solutions either protect the metallic components or the composite structure but not both effectively, and fail to manage electrostatic charge drainage.
Innovation Solution
A device comprising a conducting insert element, a conducting layer, and a fixing element that creates a low impedance path for electrical discharges, ensuring current dissipation without damaging either the composite structure or metallic components, while also incorporating sealing elements to prevent fuel leaks and using galvanically compatible materials like nickel for enhanced conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If direct riveting or conducting metallic joints are used to connect metallic components to composite material structures, then the metallic component is protected, but the composite material structure is damaged due to high electrical impedance
Solution Approach 1:
The patent introduces an intermediate installation element with a conducting layer and conducting insert that mediates between the metallic component and the composite structure. This intermediary provides a low-impedance path for electrical current while mechanically connecting to the composite material, thus protecting both the metallic component and the composite structure from electrical discharge damage.
Solution Approach 2:
The installation element combines multiple materials with different properties: a conducting layer (such as copper or aluminum) for electrical conductivity, a mechanically strong substrate for structural integrity, and potentially nickel for galvanic compatibility. This composite construction allows the single element to simultaneously provide electrical conduction, mechanical fastening, and corrosion resistance.
2Object-affected harmful factors
If metallic mesh or layer is used to protect composite material structure, then the composite structure is protected, but the metallic component is not adequately protected due to insufficient surface conductivity
Solution Approach 1:
The installation element acts as an intermediary that simultaneously protects both the composite structure and the metallic component. The conducting insert provides a low-impedance path that protects the composite structure, while the conducting layer in direct contact with the metallic component ensures adequate surface conductivity for component protection.
Solution Approach 2:
The installation element has different conducting properties at different locations: the conducting insert embedded in the composite structure provides low impedance for structural protection, while the conducting layer on the outer surface provides sufficient surface conductivity for component protection. This local differentiation of conducting quality resolves the contradiction.
3Ease of manufacture
If conventional fastening methods are used without considering electrostatic discharge paths, then installation is simple, but both structure and component are damaged by accumulated electrostatic charge
Solution Approach 1:
The installation element serves as an intermediary that inherently provides electrostatic discharge protection while maintaining installation simplicity. The conducting materials and low-impedance paths are built into the installation element itself, so that a single fastening operation simultaneously achieves both mechanical attachment and electrostatic protection.
Solution Approach 2:
The patent merges multiple functions into a single installation element: mechanical fastening, electrical conduction for lightning protection, and electrostatic discharge pathways. By combining these functions into one integrated component, the solution maintains installation simplicity while providing comprehensive protection against both atmospheric discharges and electrostatic charge accumulation.
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 device provides a controlled path for electrical discharges, preventing damage to both the composite structure and metallic components, effectively managing currents up to 100,000 amperes without causing ignition or structural damage, and ensuring safe operation even with loose fasteners, thus enhancing safety and preventing explosions in fuel-containing structures.
Implementation Method 1
the transfer of current takes place safely between the two elements... provide an appropriate path so that the current either from a discharge or from the accumulated charge from an electrostatic effect can move between the structure and the component or equipment
Implementation Method 2
which are provided with sealing elements which ensure that the composite material structures are closed in a leaktight form
Implementation Method 3
the current either from a discharge or from the accumulated charge from an electrostatic effect can move between the structure and the component or equipment without causing damage
Data Source
AI summary
A device (1) for the installation of a conducting component (2) on a structure (3) made from composite material, the inside of this structure (3) comprising a substance which can be ignited, which comprises an installation element (4) onto which the conducting component (2) is positioned, a conducting insert element (5), by means of which the installation element (4) is joined to the composite material structure (3) by its internal part, a conducting layer (6) arranged on the external part of the installation element (4) and a conducting fixing element (7) which joins the structure (3) and the installation element (4) to the insert element (5) and the conducting layer (6) so that the device (1) defines a low impedance current path through the conducting layer (6) and the insert element (5) through which the energy is dissipated from an atmospheric discharge to the component (2) or to the structure (3), the interior face of the structure (3) remaining isolated.