Fibre-Reinforced Components with Nanostructures for Conductivity

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Solution Overview

Problem

Fibre-reinforced composite materials used in civil aviation lack inherent electrical conductivity, necessitating additional solutions for electro-static discharge, electromagnetic interference shielding, and lightning strike protection, which can increase weight, manufacturing complexity, and cost when using expanded metal meshes.

Innovation Solution

Incorporating a high density of nanostructures, specifically carbon nanotubes, extending from structural fibres within a cured matrix material, to enhance electrical conductivity, with densities ranging from 10^7 to 10^11 nanostructures per cm², and potentially including graphene-doped matrix materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If expanded metal mesh is added to fibre-reinforced composite components to provide electrical conductivity, then electro-static discharge and electromagnetic interference shielding are improved, but weight, manufacturing complexity and cost increase

Engineering Contradiction:

Improveelectrical conductivityVSAvoidcomponent weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent combines the structural fibre reinforcement function with the electrical conductivity function by growing carbon nanotubes directly on the structural fibres. This merging eliminates the need for separate expanded metal mesh layers, thereby maintaining electrical conductivity while reducing weight and simplifying the component structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a hierarchical composite structure where carbon nanotubes are integrated with structural fibres to form a hybrid material system. This composite approach provides both mechanical strength from the fibres and electrical conductivity from the nanotubes, resolving the contradiction between reliability and weight.

Inventive Principle:

Principle #40Composite materials

2Reliability

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the structural and electrical functions into a single integrated component by growing carbon nanotubes on the fibres during manufacturing. This eliminates the need for separate mesh attachment processes, reducing manufacturing complexity while maintaining electrical conductivity reliability.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If high density of carbon nanotubes is grown on structural fibres, then electrical conductivity is significantly improved, but manufacturing process complexity increases

Engineering Contradiction:

Improveelectrical conductivityVSAvoidmanufacturing process ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary catalytic coating to the structural fibres before carbon nanotube growth. This preliminary action enables controlled nanotube formation with high density and uniform distribution, achieving excellent electrical conductivity while managing manufacturing complexity through process optimization.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent optimizes manufacturing parameters including catalytic coating composition, carbon source concentration, temperature, and pressure to achieve high-density nanotube growth. By carefully controlling these parameters, the process achieves excellent electrical conductivity while maintaining reasonable manufacturing ease.

Inventive Principle:

Principle #35Parameter changes

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 integration of nanostructures significantly improves electrical conductivity, reducing the need for additional shielding materials, while maintaining mechanical properties and potentially enhancing thermal conductivity and interfacial adhesion, thus addressing the limitations of traditional fibre-reinforced composites.

Implementation Method 1

a plurality of nanostructures extending from one or more of the structural fibres, a density of the nanostructures being at least about 10^7 per cm², thereby improving the electrical conductivity of the component

Methodology Applied

Scientific EffectElectron transport: Conduction (electrical)

Implementation Method 2

The matrix material may be doped with graphene

Methodology Applied

Scientific EffectGraphene conduction: Conduction (electrical)

Data Source

PatentEP4223501A1Fibre-reinforced components including nanostructures

Publication Date: 2023.08.09 SHORT BROTHERS PLC

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Figure 4A~4B

AI summary

Components having fibre-reinforced composite structures are disclosed. The component comprises a plurality of structural fibres embedded in a cured matrix material and a plurality of nanostructures such as carbon nanotubes extending from one or more of the structural fibres.