Conductive Fiber Composite Structure for Gas Turbine Harness Replacement
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Solution Overview
Problem
Conventional electrical harnesses in gas turbine engines are bulky, heavy, difficult to manipulate, and prone to mechanical damage, complicating assembly and maintenance, and are susceptible to errors due to their complex nature and susceptibility to mechanical stress.
Innovation Solution
A composite structure using electrically conductive reinforcement fibers within a polymer matrix, with insulating barriers to divide the material into portions at different electrical potentials, allowing electrical signals to be transmitted through the fibers, potentially replacing traditional wire harnesses and reducing the risk of mechanical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wire harnesses are used to transmit electrical signals, then electrical connectivity is achieved, but the system becomes bulky, heavy, and difficult to manipulate
Solution Approach 1:
The patent merges the structural support function and electrical conduction function into a single integrated composite structure. The reinforcement fibers serve dual purposes: providing mechanical strength and acting as electrical conductors, thereby eliminating the need for separate wire harnesses and reducing bulk while maintaining electrical connectivity.
Solution Approach 2:
The invention uses composite materials consisting of a polymer matrix reinforced with electrically conductive fibers. This composite structure provides both mechanical reinforcement and electrical conduction pathways, creating a lightweight alternative to conventional metal wire harnesses that is easier to manipulate while maintaining reliability.
2Reliability
If conventional wire harnesses with multiple components are used, then electrical signals can be transmitted, but assembly and maintenance become complicated and time-consuming
Solution Approach 1:
The patent combines multiple separate components (wires, insulators, connectors, brackets) into a single integrated composite structure. The reinforcement fibers are embedded directly in the polymer matrix during manufacturing, creating a pre-assembled unit that requires no separate assembly steps, thereby reducing assembly and maintenance time while maintaining electrical signal transmission capability.
3Reliability
If conventional wire harnesses are used, then electrical conductors can be protected, but the protective measures add weight and reduce manipulability
Solution Approach 1:
The invention uses composite materials where the polymer matrix itself provides the protective function. The matrix material surrounds and protects the reinforcement fibers during manufacturing and service, eliminating the need for separate protective sleeves or braiding that would add weight. The composite structure provides inherent protection while maintaining low weight and high manipulability.
4Adaptability or versatility
If reinforcement fibers are made electrically conductive, then the composite structure can transmit electrical signals, but the fibers may be susceptible to electrical damage
Solution Approach 1:
The patent introduces insulating barriers as intermediary elements between different electrical potentials within the composite structure. These barriers prevent direct electrical contact between conductive fibers at different potentials, protecting the electrically conductive reinforcement fibers from electrical damage while allowing the composite structure to transmit electrical signals through controlled pathways.
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 provides a lightweight, robust, and flexible means of transmitting electrical signals, reducing assembly and maintenance time, minimizing errors, and offering fault tolerance by eliminating single points of failure, while allowing for easier integration of new electrical units and improved protection of electrical conductors.
Implementation Method 1
the continuous fibres being electrically conductive, and the structure having electrodes electrically connected to the continuous fibres
Implementation Method 2
one or more insulating barriers which electrically divide the structure so that a first portion of the material in electrical contact with one of the electrodes can be held at a different electrical potential to a second portion
Data Source
AI summary
A composite structure is provided. The structure is formed of rigid composite material in which non-metallic continuous fibers reinforce a polymer matrix. The continuous fibers are electrically conductive. The structure has electrodes electrically connected to the continuous fibers. The composite material contains one or more insulating barriers which electrically divide the structure so that a first portion of the material in electrical contact with one of the electrodes can be held at a different electrical potential to a second portion of the material in electrical contact with the other electrode. In use, an electrical unit can be provided to electrically bridge the first and second portions of the material such that electrical signals can be transmitted between the electrodes and the electrical unit via the continuous fibers.