Direct Write Conductive Pathways for Composite Lightning Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Composite materials used in aircraft structures face challenges in dissipating electric charge from lightning strikes and static buildup efficiently, as they are less conductive than metallic materials, and existing solutions often require additional metallic components that can be cumbersome and increase manufacturing complexity and cost.
Innovation Solution
An electrical conductor pathway system using a direct write printing process to create a conductive material pattern on a substrate with grounding points, forming interconnected pathways to divert electric charges, which includes a primer layer, conductive coating, and topcoat for enhanced conductivity and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If metallic conductors or metal foil systems are added to composite structures to manage lightning strikes and static buildup, then electrical conductivity is improved, but device complexity and manufacturing complexity increase
Solution Approach 1:
The conductive pathway system is integrated directly into the composite structure during manufacturing, merging the lightning protection function with the structural component itself. This eliminates the need for separate metallic conductor additions and reduces overall system complexity.
Solution Approach 2:
The composite structure serves multiple functions: it provides structural support and simultaneously manages electrical conductivity through integrated conductive pathways. This multi-functionality eliminates the need for separate dedicated lightning protection components.
2Reliability
If metallic diverter strips are applied to composite structures to manage electric charge, then electrical conductivity is improved, but weight increases
Solution Approach 1:
The conductive pathways are combined with the composite structure itself, eliminating the need for separate metallic diverter strips. This integration maintains electrical conductivity while avoiding additional weight from separate metallic components.
3Reliability
If embedded metallic mesh is incorporated into composite structures to manage lightning strikes, then electrical conductivity is improved, but manufacturing complexity increases
Solution Approach 1:
The conductive pathways are merged into the composite manufacturing process itself, allowing conductive materials to be deposited directly during structure fabrication. This eliminates complex post-manufacturing steps for incorporating metallic mesh.
Solution Approach 2:
Conductive pathways are deposited and integrated during the composite manufacturing process before final assembly, rather than requiring complex post-manufacturing installation of metallic mesh systems.
4Reliability
If applique-based systems with continuous conductive layers are applied to composite surfaces, then electrical conductivity is improved, but ease of repair decreases
Solution Approach 1:
The conductive pathways are formed as discrete, addressable patterns rather than continuous layers, allowing individual pathways to be targeted for repair or replacement without affecting the entire system.
Solution Approach 2:
The conductive pathways are deposited as thin, flexible patterns that can be applied directly to composite surfaces and are compatible with standard composite repair procedures.
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 system effectively manages electric charge dissipation from lightning strikes and static buildup on composite aircraft surfaces, improving conductivity and reducing manufacturing complexity and costs by integrating the conductive pathways directly into the aircraft structure during production.
Implementation Method 1
a direct write conductive material pattern printed or deposited directly onto the first surface via the direct write printing process
Implementation Method 2
The direct write conductive material pattern forms one or more electrical pathways interconnected with the one or more grounding points. The one or more electrical pathways interconnected with the one or more grounding points divert the electric charge from the first surface to the one or more grounding points
Data Source
Figure 1A
Figure 1B~1C
Figure 2~3
AI summary
The disclosure provides in one embodiment an electrical conductor pathway system for diverting an electric charge. The electrical conductor pathway system includes a substrate having a first surface to be printed on and having one or more grounding points. The electrical conductor pathway system further includes a direct write conductive material pattern printed directly onto the first surface via a direct write printing process. The direct write conductive material pattern forms one or more electrical pathways interconnected with the one or more grounding points. The one or more electrical pathways interconnected with the one or more grounding points divert the electric charge from the first surface to the one or more grounding points.