Conductive Coating for Polymer Aircraft Lightning Protection
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Solution Overview
Problem
Rotary wing aircrafts with fiber reinforced polymer components are more prone to lightning strikes due to their higher electrical resistance compared to traditional aluminum components, requiring effective electrical bonding and grounding to prevent damage from lightning direct and indirect effects, while conventional electrical connections are costly and increase aerodynamic resistance.
Innovation Solution
Implementing a structural arrangement with fiber reinforced polymer components interconnected via a sprayed layer of electrically conductive particles using thermal gas spray technology, reducing electrical resistance to less than 1 mΩ and providing a cost-effective, aerodynamically favorable solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical connections (copper splices with adhesive and riveting) are used to connect fiber reinforced polymer components, then electrical bonding and grounding for lightning protection is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts the electrical conductivity function from the mechanical connection structure. Instead of using complex copper splices with adhesive and riveting, the invention applies electrically conductive paint directly to the fiber reinforced polymer components, separating the electrical bonding function from the mechanical fastening function and achieving lightning protection through a simpler coating application process
Solution Approach 2:
The patent replaces the mechanical electrical connection system (copper splices, adhesive, rivets) with an electrochemical system (electrically conductive paint coating). This substitution eliminates the need for complex mechanical assembly while maintaining electrical conductivity for lightning protection, reducing both manufacturing complexity and cost
2Reliability
If conventional electrical connections are used to interconnect fiber reinforced polymer components, then electrical grounding is achieved, but aerodynamic resistance increases due to surface disruption
Solution Approach 1:
The patent uses a thin film coating of electrically conductive paint applied to the surface of the fiber reinforced polymer components. This thin film provides the necessary electrical grounding while maintaining a smooth surface that does not significantly disrupt airflow, thereby minimizing aerodynamic resistance compared to protruding copper splices and rivets
Solution Approach 2:
The patent applies electrically conductive paint only at specific locations where electrical connection is needed (at predefined distances depending on installed equipment), rather than requiring continuous metallization of entire component surfaces. This localized application maintains aerodynamic efficiency while achieving the required electrical grounding at critical points
3Weight of moving object
If fiber reinforced polymer components are used in rotary wing aircraft, then weight reduction is achieved, but vulnerability to lightning strikes increases due to higher electrical resistance
Solution Approach 1:
The patent creates a composite structure by combining the fiber reinforced polymer component with a coating of electrically conductive paint. This composite approach maintains the lightweight advantage of polymer components while adding the electrical conductivity necessary for lightning protection, effectively combining the benefits of both material types
Solution Approach 2:
The electrically conductive paint acts as an intermediary layer between the non-conductive fiber reinforced polymer component and the lightning strike. This intermediate coating provides the necessary electrical pathway for lightning current while allowing the underlying polymer structure to remain lightweight, mediating between the conflicting requirements of weight reduction and 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
The solution achieves a high-quality, low-resistance electrical connection between fiber reinforced polymer components, enhancing lightning protection while reducing costs and maintaining a smooth outer surface, thus addressing the increased vulnerability of fiber reinforced polymer components to lightning strikes.
Implementation Method 1
sprayed layer of electrically conductive particles which is provided in the interspace by means of a thermal gas spray technology
Data Source
AI summary
A rotary wing aircraft that comprises a structural arrangement with at least one first fiber reinforced polymer component and at least one second fiber reinforced polymer component that are spaced apart from each other by an interspace and that are rigidly attached to an associated structural component, wherein the at least one first fiber reinforced polymer component and the at least one second fiber reinforced polymer component are at least partly interconnected by means of an electrically conductive connection, and wherein the electrically conductive connection comprises at least one sprayed layer of electrically conductive particles, the at least one sprayed layer of electrically conductive particles being provided in the interspace.