Conductive Insulative Composite for Aerospace Structural Integration

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Solution Overview

Problem

Existing composite materials used in aerospace, aircraft, and other applications lack integrated solutions for both structural reinforcement and electrical conductivity, requiring separate layers for strength and electrical connectivity, which can increase weight and complexity.

Innovation Solution

A composite structure that embeds insulated electrical conductors within fiber-reinforced polymer (FRP) to provide both structural stiffness and electrical connectivity, using adhesively bonded and encapsulated conductive bus bars with insulative layers, allowing for the integration of electrical components within the structural framework.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If separate layers are used for structural reinforcement and electrical connectivity, then structural strength is improved, but device complexity and weight increase

Engineering Contradiction:

Improvestructural strengthVSAvoiddevice complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent combines structural reinforcement and electrical connectivity functions into a single integrated layer. Conductive fibers are embedded within the fiber-reinforced polymer matrix, allowing the same layer to provide both mechanical strength and electrical conduction pathways, thereby eliminating the need for separate layers and reducing overall device complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The fiber-reinforced polymer layer is designed to serve multiple functions simultaneously: it provides structural reinforcement through the fiber matrix while also providing electrical connectivity through embedded conductive fibers. This multi-functional design reduces the number of components needed and simplifies the overall device structure

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If separate layers are used for structural reinforcement and electrical connectivity, then structural strength is improved, but weight increases

Engineering Contradiction:

Improvestructural strengthVSAvoidweight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

By merging structural and electrical functions into a single layer, the patent eliminates the additional weight that would result from stacking separate structural and electrical layers. The conductive fibers are integrated within the polymer matrix without requiring additional structural support layers

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If conductive fibers are embedded in fiber-reinforced polymer, then electrical connectivity is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improveelectrical connectivityVSAvoidmanufacturing precision

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The conductive fibers are pre-aligned and positioned within the polymer matrix before curing. This preliminary arrangement ensures proper electrical connectivity pathways are established before the final structural form is set, reducing the need for post-manufacturing adjustments and simplifying the overall manufacturing process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent utilizes changes in material properties during the curing process to lock in the desired fiber arrangement. By controlling the transition from uncured to cured state, the manufacturing process achieves precise fiber positioning without requiring extremely tight tolerances during assembly

Inventive Principle:

Principle #35Parameter changes

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 approach enhances structural properties while enabling efficient electrical connectivity within the composite structure, reducing weight and complexity by eliminating the need for separate electrical cables and enhancing mechanical properties.

Implementation Method 1

A composite structure that embeds insulated electrical conductors within fiber-reinforced polymer (FRP) to provide both structural stiffness and electrical connectivity

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

using adhesively bonded and encapsulated conductive bus bars with insulative layers

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS10176905B2Electrically conductive and insulative composite

Publication Date: 2019.01.08 WISK AERO LLC

AI summary

An electrically conductive and insulative composite (ECIC) is disclosed. In various embodiments, an ECIC as disclosed herein may include an electrically conductive structural element and one or more electrically insulative structural elements adhesively bonded to the conductive structural element to form a unitized structure having a design shape and one or more significant mechanical properties. The conductive structural element is substantially encapsulated by said one or more electrically insulative structural elements with the exception of one or more contact areas comprising portions of conductive material not encapsulated by said one or more electrically insulative structural elements.