Conductive Laminated Composite Material for Aircraft Lightning Protection

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Solution Overview

Problem

Thermosetting resin-based laminated composite materials used in aircraft airframes have poor electronic interference shielding and lightning protection due to their nonconductive nature, and existing methods to improve electrical conductivity often compromise impact resistance.

Innovation Solution

A thickness direction conductive laminated composite material is developed, comprising layers of carbon fibers with a curable resin and integrated electrically conductive materials such as conductive fibers, films, Z-pins, or particles, ensuring at least 40% carbon fiber volume, which enhances electrical conductivity without compromising impact resistance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If electrically conductive materials are added to improve electrical conductivity, then shielding and lightning protection ability is improved, but impact resistance deteriorates

Engineering Contradiction:

Improveelectrical conductivityVSAvoidimpact resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses composite materials by integrating electrically conductive materials (such as metalized fibers, conductive particles, or thin films) into the carbon fiber reinforced polymer matrix. This creates a multi-functional composite that simultaneously provides structural strength, electrical conductivity for shielding, and impact resistance, resolving the contradiction between electrical performance and mechanical strength

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent achieves multi-functionality by designing a laminated composite material that simultaneously performs structural support, electrical shielding, and lightning protection functions. The carbon fiber layers provide structural strength while the integrated electrically conductive materials provide electrical conductivity, allowing a single material system to fulfill multiple requirements without compromising impact resistance

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Strength

If carbon fiber content is increased to improve impact resistance, then impact resistance is improved, but electrical conductivity in thickness direction deteriorates

Engineering Contradiction:

Improveimpact resistanceVSAvoidelectrical conductivity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent employs composite materials by combining high-volume carbon fiber layers (providing impact resistance) with integrated electrically conductive materials arranged in specific patterns or orientations. This composite structure ensures that the carbon fiber content remains high for structural integrity while the conductive materials provide sufficient electrical pathways in the thickness direction

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by strategically positioning electrically conductive materials at specific locations within the laminate structure, such as at layer interfaces or in alternating layers, rather than uniformly distributing them. This allows the majority of the material to be carbon fiber for impact resistance, while localized conductive elements provide the necessary electrical conductivity pathways

Inventive Principle:

Principle #3Local quality

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 significantly improves electrical conductivity in the thickness direction while maintaining or enhancing impact resistance, offering superior shielding and lightning protection with higher in-plane conductivity and electrical power transmission performance compared to traditional materials.

Implementation Method 1

a electrically conductive material... significantly improves electrical conductivity in the thickness direction... superior shielding and lightning protection with higher in-plane conductivity and electrical power transmission performance

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20220270780A1Thickness direction conductive laminated composite material and manufacturing method therefor

Publication Date: 2022.08.25 BEIJING MEGA MATERIAL INNOVATION WORK M2IW CO LTD

AI summary

A thickness direction conductive laminated composite material, comprising: laminated multiple layers of carbon fiber; a curable resin which is disposed among the laminated multiple layers of carbon fiber, coats the laminated multiple layers of carbon fiber and bonds the laminated multiple layers of carbon fiber together; and a conductive material, the conductive material comprising at least one of the followings: a conductive fiber woven together with the carbon fiber, an interlayer conductive film, an interlayer conductive Z-pin and an interlayer conductive particle. The carbon fiber accounts for 40 vol % or more of the thickness direction conductive laminated composite material. The thickness direction conductive laminated composite material has higher thickness direction conductivity, planar conductivity and electric energy transmission performance than traditional laminated composite materials.