Embedded Conductive Composite Layup for Lightweight Aircraft Wiring
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Solution Overview
Problem
Electrical wires in aircraft face challenges such as weight, insulation needs, abrasion, and electromagnetic interference, requiring additional support and protection while maintaining conductivity and minimizing interference.
Innovation Solution
Embedding conductive layers within fiber-reinforced plastic composites allows for integrated electrical pathways with reduced need for insulation, support structures, and natural electromagnetic shielding, compatible with automated manufacturing methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional electrical wires are used in aircraft, then electrical conductivity is achieved, but weight increases and additional insulation and support structures are required
Solution Approach 1:
The patent combines the electrical conductor with the composite structure by embedding conductive layers within the fiber-reinforced plastic plies. This merging eliminates the need for separate wires, insulation, and support structures, thereby reducing weight while maintaining electrical conductivity functionality within the integrated composite material.
Solution Approach 2:
The invention creates a composite material system where conductive layers are integrated within the composite plies. This composite approach allows the structure to simultaneously provide mechanical support and electrical conductivity, eliminating the need for separate wire assemblies and their associated insulation and mounting hardware.
2Device complexity
If traditional wires are used with insulation and support structures, then electrical isolation and support are achieved, but device complexity increases
Solution Approach 1:
The patent merges the functions of structural support and electrical isolation into the composite plies themselves. The prepreg layers provide both mechanical support and electrical isolation simultaneously, eliminating the need for separate insulation materials and support structures, thereby reducing overall device complexity.
Solution Approach 2:
The composite plies serve multiple functions: they provide structural support, electrical isolation, and embedding medium for conductors all in one component. This multi-functionality reduces the number of separate components needed, simplifying the overall system while maintaining reliable electrical isolation.
3Ease of manufacture
If conductors are embedded within composite plies, then weight is reduced and integration is improved, but manufacturing precision requirements increase
Solution Approach 1:
The conductive layers are placed within the composite plies during the manufacturing process itself, before final curing. This preliminary action allows for precise positioning to be established during layup, and the subsequent curing process locks this positioning in place, ensuring manufacturing precision is achieved during the integration phase.
4Productivity
If automated manufacturing methods are used, then productivity increases, but manufacturing precision control becomes more challenging
Solution Approach 1:
The invention changes the physical state of the composite material from uncured (malleable) to cured (rigid) to lock in the conductor positioning. This parameter change from viscous to solid state during the curing process ensures that automated placement achieves the required precision and maintains it through subsequent handling and assembly operations.
Data Source
AI summary
Fiber-reinforced composites is provided. The composites include a plurality of prepreg layers, each comprising a polymeric resin and a plurality of fibers disposed therein; and at least one electrically-conductive layer at least partially embedded in the plurality of prepreg layers. These fiber-reinforced composites can save weight relative to externally provided wires and can be provided in forms suitable for use in automated fiber placement and automated tape layup machines. Advantageous applications include uses in lightning strike protection, energy storage, signal transmission, and power distribution.