Conductive Resin Layer Structure for Through-Thickness Composite Bonding
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Solution Overview
Problem
Composite materials lack sufficient electrical conductivity in the z-direction, making them vulnerable to electromagnetic hazards like lightning strikes, and existing methods to enhance conductivity often compromise mechanical properties.
Innovation Solution
Incorporating a skeletal structure within the resin layer, comprising studs extending through the thickness and a framework in the plane, which can be made of conductive materials or polymers with conductive coatings, to provide a three-dimensional network for electrical conduction while maintaining mechanical integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a discrete resin layer is included in the composite material, then mechanical properties are improved, but electrical conductivity in the z-direction deteriorates
Solution Approach 1:
The resin layer comprises a composite structure combining resin matrix with conductive elements (carbon fibres, metal particles, or conductive coatings) to achieve both mechanical support and electrical conductivity functions simultaneously, resolving the contradiction between mechanical integrity and electrical conductivity
Solution Approach 2:
The invention introduces conductive elements specifically within the resin layer at locations where electrical conductivity is needed, while maintaining the resin's mechanical properties in other areas, creating local functional differentiation
2Reliability
If conductive elements are added to enhance electrical conductivity, then electrical conductivity in the z-direction is improved, but mechanical properties deteriorate
Solution Approach 1:
The resin layer is formulated as a composite material where conductive elements (carbon fibres, metal particles, or conductive coatings) are integrated into the resin matrix, allowing simultaneous achievement of electrical conductivity and mechanical strength through synergistic material combination
Solution Approach 2:
The invention optimizes the concentration, distribution, and arrangement of conductive elements within the resin layer to achieve sufficient electrical conductivity while maintaining mechanical integrity, balancing the parameters of conductivity and strength
3Strength
If adhesive layers of resin are added to the composite material, then bonding between layers is improved, but electrical conductivity deteriorates
Solution Approach 1:
The adhesive layer is formulated as a composite resin material containing conductive elements, enabling it to simultaneously provide adhesive bonding between structural layers and maintain electrical conductivity pathways across the laminate thickness
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 skeletal structure enhances electrical conductivity in the z-direction, achieving conductivities exceeding 70 S/m, while maintaining or improving mechanical properties without significantly increasing the resin layer's volume.
Implementation Method 1
The skeletal structure enhances electrical conductivity in the z-direction, achieving conductivities exceeding 70 S/m
Data Source
AI summary
A resin layer, having a generally planar form and having a first outer face and an essentially parallel second outer face, and supported on its first outer face by a supporting structure, parallel to and in contact with the first outer face, wherein the layer comprises a skeletal structure embedded within the resin, the skeletal structure comprising: a plurality of studs distributed throughout the plane of the layer, each stud having a length in the direction perpendicular to the plane of the layer, and terminating in a first end and a second end, the studs having a length extending from at least the first face to at least the second face; and a framework of solid connections, connecting each solid stud to a plurality of adjacent studs, particularly for use as part of a prepreg.