Embedded Metallic Meshes in Composite Structures
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Solution Overview
Problem
Conventional electrical harnesses in gas turbine engines are bulky, heavy, difficult to manipulate, and prone to mechanical damage, complicating assembly and maintenance, while also occupying significant space and weight.
Innovation Solution
A composite structure using rigid composite material with reinforced polymer matrix and embedded electrically conductive metallic meshes, allowing for the transmission of electrical signals between electrodes and electrical units, reducing the need for separate signal transmission arrangements and providing robustness against mechanical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional wiring harnesses are used to transmit electrical signals, then electrical connectivity is achieved, but the system becomes bulky, heavy, and occupies significant space
Solution Approach 1:
The patent merges the structural composite material with electrical signal transmission functionality by embedding conductive metallic meshes within the composite layers. This integration eliminates the need for separate wiring harnesses, as the composite structure itself becomes the electrical conduit, thereby reducing weight while maintaining electrical connectivity
Solution Approach 2:
The composite structure serves multiple functions simultaneously: it provides mechanical strength and structural integrity while also transmitting electrical signals through the embedded meshes. This multi-functionality replaces the conventional separation of structural components and electrical wiring, reducing overall system weight and space
2Object-affected harmful factors
If conventional wiring harnesses with protective sleeves and braiding are used, then mechanical protection is provided, but the harness becomes more difficult to manipulate and heavier
Solution Approach 1:
The protective function is merged into the composite material matrix itself, which inherently provides mechanical protection to the embedded conductive meshes. The composite structure's toughness and flexibility protect the electrical pathways without requiring additional protective sleeves or braiding, thereby maintaining ease of manipulation
Solution Approach 2:
The use of composite materials with inherent toughness and flexibility provides mechanical protection to the embedded meshes. The composite structure absorbs mechanical stresses and protects the electrical pathways without adding heavy protective coverings, maintaining ease of installation and manipulation
3Reliability
If conventional wiring harnesses with multiple components are used, then electrical connectivity is achieved, but assembly and maintenance become complicated and time-consuming
Solution Approach 1:
The patent combines multiple functions (structural support, electrical signal transmission, and mechanical protection) into a single integrated composite structure. This eliminates the need for assembling multiple separate components (wires, sleeves, connectors, brackets), thereby simplifying both initial assembly and maintenance operations
Solution Approach 2:
The composite structure with embedded meshes serves as a universal component that simultaneously provides mechanical strength and electrical connectivity. This multi-functionality reduces the number of separate components needed, simplifying assembly procedures and reducing maintenance complexity
4Reliability
If conventional wiring harnesses are used, then electrical signals can be transmitted, but the conductors are susceptible to mechanical damage during installation and service
Solution Approach 1:
The conductive meshes are merged within the composite material matrix, which provides inherent mechanical strength and protection. The composite structure shields the electrical pathways from mechanical damage during installation and service, eliminating the vulnerability of exposed conductors in conventional harnesses
Solution Approach 2:
The composite material matrix provides mechanical strength and protection to the embedded conductive meshes. This integration ensures that the electrical pathways are protected from mechanical damage while maintaining signal transmission capability, overcoming the weakness of conventional exposed wiring
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 composite structure simplifies signal transmission, reduces weight and size, enhances durability, and minimizes the risk of mechanical damage, thereby streamlining assembly and maintenance processes while providing flexible and fault-tolerant electrical connectivity.
Implementation Method 1
first and second electrically conductive metallic meshes embedded therein, and respective electrodes electrically connected to the meshes
Data Source
AI summary
A composite structure is provided. The structure is formed of rigid composite material in which particulates or fibers reinforce a polymer matrix. The structure has first and second electrically conductive metallic meshes embedded therein, and respective electrodes electrically connected to the meshes. The first and second meshes are electrically isolated from each other in the composite material so that the meshes can be held at different electrical potentials to each other. In use, an electrical unit can be provided to electrically bridge the first and second meshes such that electrical signals can be transmitted between the electrodes and the electrical unit via the meshes.