Conductive Composite Layer for Aircraft Static Dissipation
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Solution Overview
Problem
Composite materials used in aerospace platforms, such as fuel tanks, lack sufficient conductivity to dissipate static electricity effectively, leading to potential electrical discharges and increased complexity and weight when additional dissipation mechanisms are employed.
Innovation Solution
A composite structure comprising a first composite layer and a second composite layer, where the second layer is treated with a conductive material to dissipate electric charges and limit electrical current flow caused by electromagnetic events, with a primer layer aiding in charge dissipation and integrated into the structure during manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used in fuel tanks, then weight is reduced, but conductivity is insufficient leading to static electricity buildup
Solution Approach 1:
The patent applies composite materials by integrating a conductive layer within the composite fuel tank structure. The conductive layer is embedded between structural composite layers, creating a multi-layer composite system that provides both structural integrity and electrical conductivity for static dissipation while maintaining the weight advantages of composite materials.
Solution Approach 2:
The patent merges multiple functions into a single integrated structure: the conductive layer serves both as an electrical pathway for static dissipation and as part of the structural composite system. This eliminates the need for separate grounding systems or additional dissipation mechanisms, reducing overall complexity while maintaining both weight reduction and reliable static electricity dissipation.
2Reliability
If additional dissipation mechanisms are added to composite structures, then static electricity dissipation is improved, but device complexity and weight increase
Solution Approach 1:
The conductive layer is integrated directly into the composite structure during manufacturing, merging the dissipation function with the structural system. This eliminates the need for separate dissipation mechanisms such as external grounding wires, coatings, or additives, thereby reducing device complexity while ensuring reliable static electricity dissipation.
Solution Approach 2:
The conductive layer performs multiple functions simultaneously: it provides a pathway for static electricity dissipation, maintains structural integrity as part of the composite laminate, and reduces the need for additional specialized components. This multi-functionality reduces overall system complexity while achieving reliable dissipation.
3Reliability
If conductive materials are added to composite layers, then static electricity dissipation is improved, but manufacturing complexity increases
Solution Approach 1:
The conductive layer is incorporated into the composite structure during the preliminary manufacturing stages, specifically during the laminate fabrication process. The conductive material is placed between structural layers before curing, allowing it to be integrated into the final structure without requiring post-manufacturing modifications or additional processing steps.
Solution Approach 2:
The conductive layer is manufactured as part of the composite laminate system using similar manufacturing processes (such as autoclave curing or resin transfer molding). This approach allows the conductive layer to be integrated seamlessly with the structural composite layers, maintaining ease of manufacture while achieving reliable electric charge dissipation.
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 solution reduces the risk of electrical discharges, minimizes weight and complexity, and integrates charge dissipation seamlessly into the structure, reducing manufacturing time and costs by eliminating the need for additional dissipation systems.
Implementation Method 1
The second composite layer comprises a resin treated with a conductive material configured to dissipate an electric charge on a surface of the structure
Implementation Method 2
a primer layer, located between the second composite layer and an interior of the structure, the primer layer configured to aid in dissipating the electric charge
Data Source
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AI summary
A method and apparatus comprising a first composite layer and a second composite layer in which the second composite layer is associated with the first composite layer. The first composite layer and the second composite layer form a structure. The second composite layer has a conductivity configured to dissipate an electric charge on a surface of the structure and limit a flow of an electrical current in the second composite layer in which the electrical current is caused by an electromagnetic event.