Conductor in Composite for Electric Aircraft Weight Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The weight of conductive materials and insulation in electric wires used to connect batteries to motors in electric aircraft and vehicles can significantly impact performance, such as maximum speed and handling, due to the need for sufficient size to support electrical load.
Innovation Solution
Incorporating conductive structures into composite materials, such as carbon fiber reinforced layers, to create lightweight electrical connections that reduce weight while maintaining sufficient current carrying capacity, with conductors located near the surface for enhanced cooling and reduced cross-sectional area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional insulated wires are used to connect batteries to motors, then sufficient electrical load support is achieved, but significant weight is added to the aircraft
Solution Approach 1:
The patent applies composite materials by integrating conductive structures directly into the carbon fiber reinforced polymer (CFRP) composite panels. The conductive paths are formed using carbon fiber bundles or conductive ink printed on the composite surface, eliminating the need for separate traditional insulated wires. This integration reduces overall weight while maintaining electrical conductivity for power transmission from batteries to motors.
2Weight of moving object
If conductor size is reduced to minimize weight, then aircraft weight decreases, but current carrying capacity may be insufficient
Solution Approach 1:
The patent applies local quality by positioning conductive structures near the surface of the composite panels where thermal dissipation is most effective. The conductive paths are strategically located to maximize cooling from ambient airflow, allowing thinner conductors to carry high currents without overheating. This localized optimization of conductor placement enables reduced cross-sectional area while maintaining adequate current carrying capacity through enhanced heat dissipation at the surface.
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 minimizes the overall weight of the aircraft or vehicle by allowing thinner conductors to carry high currents, improving performance and reducing electromagnetic interference through strategic placement and design.
Implementation Method 1
electric wires or cables are run from the batteries to the motors
Implementation Method 2
conductor in a composite structure... with conductors located near the surface for enhanced cooling
Data Source
AI summary
A conductor in composite is disclosed. In various embodiments, an electrically conductive structure, such as an electrically conductive metal, is sandwiched between insulating material and two or more layers of fiber reinforced composite material, to form a stack that is used to form a composite structure that includes the electrically conductive layer. The layer may comprise an electrical line, trace, bus, etc. to conduct electricity from one location to another within the composite structure, such as to connect a battery or other power source at one location to an electrical load at another location.