Conductive Carbon Fiber Composite for Lightning Dissipation
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Solution Overview
Problem
Composite parts made with carbon fibers and thermosetting resins lack sufficient transverse electrical conductivity, which is crucial for lightning dissipation and current return in aeronautical structures, while adding metal components increases mass and cost.
Innovation Solution
A material comprising unidirectional carbon fibers linked with a conductive component, such as particles or fibers, integrated with a permeable thermoplastic or thermosetting material layer, allowing for resin infusion and providing improved electrical conductivity without significant weight or cost penalties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metal components are added to provide transverse electrical conductivity, then electrical conductivity is improved, but mass and cost increase
Solution Approach 1:
The patent changes the material parameter from metal to carbon-based conductive elements, maintaining electrical conductivity function while significantly reducing density and mass. Carbon particles or fibers are used instead of metal ribbons or braids, providing the necessary transverse conductivity without the weight penalty of metallic components.
Solution Approach 2:
The invention creates a composite structure combining carbon fibers (for mechanical strength and longitudinal conductivity) with carbon-based conductive particles or fibers (for transverse conductivity). This multi-component composite achieves both electrical conductivity requirements and weight reduction, avoiding the need for separate metal components.
2Reliability
If metal components are added to provide transverse electrical conductivity, then electrical conductivity is improved, but cost increases
Solution Approach 1:
The patent substitutes expensive metal components with carbon-based alternatives, changing the material parameter to achieve cost reduction. Carbon particles or fibers are significantly cheaper than metal ribbons or braids while providing equivalent or superior electrical conductivity performance for aeronautical applications.
Solution Approach 2:
The composite material system integrates carbon fibers and carbon-based conductive elements, eliminating the need for separate metal components. This unified carbon-based composite reduces material costs, manufacturing complexity, and assembly requirements compared to hybrid metal-composite structures.
3Strength
If resin layers are added between carbon fiber layers, then mechanical properties are improved, but transverse electrical conductivity deteriorates
Solution Approach 1:
The patent applies local quality by differentiating the functional properties of different layers: carbon fiber layers provide mechanical strength and longitudinal conductivity, while the resin layers are enhanced with carbon-based conductive particles or fibers to provide transverse conductivity. Each layer is optimized for its specific function while contributing to the overall performance.
Solution Approach 2:
The invention creates a multi-layer composite structure where resin layers are reinforced with carbon-based conductive additives. This transforms the traditionally insulating resin layers into conductive layers, enabling them to simultaneously provide mechanical bonding between carbon fiber layers and contribute to transverse electrical conductivity.
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 enhances transverse electrical conductivity of composite parts, meeting aeronautical requirements while maintaining mechanical properties and reducing material mass.
Implementation Method 1
A material comprising unidirectional carbon fibers linked with a conductive component, such as particles or fibers, integrated with a permeable thermoplastic or thermosetting material layer
Implementation Method 2
integrated with a permeable thermoplastic or thermosetting material layer, allowing for resin infusion
Data Source
Figure 1~2B
Figure 3A~4E
AI summary
The invention relates to a material (I) suitable for the production of composite parts via a process in which an external thermosetting or thermoplastic matrix is diffused within said material, comprising at least one web (1) of unidirectional carbon fibres (2) that is combined, on at least one of its faces, with at least one conductive component (5) combined with or integrated into a permeable layer (3a, 3b, 10) made of a thermoplastic material or made of a mixture of thermoplastic and thermosetting materials, said permeable layer being in the form of a woven fabric, a powder, a porous film, a knit, or, preferably, a non woven fabric (3a, 3b, 10), to a process for manufacturing composite parts using such a material and to the composite parts thereof being capable of being obtained by such a process.