Flexible Circuit Bridge for Composite Laminate Electrical Connections

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Solution Overview

Problem

The efficient manufacturing of composite laminates with embedded layers and connectors is hindered by dimensional changes during resin curing, leading to stress at connection points and labor-intensive in-place assembly, and the integration of internal wires or custom detailing is complicated by undesired wrinkles or bulges.

Innovation Solution

A flexible circuit is used to bridge the electrical connection between an embedded conductive layer and a connector, accommodating spatial displacement during curing and eliminating the need for special custom-molded conductors or in-place assembly, by being integrated into the laminate forming process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a direct connection between embedded layer and connector is made, then electrical connection is established, but stress develops during resin curing compromising connection integrity

Engineering Contradiction:

Improveconnection integrityVSAvoidstress at connection

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The flexible circuit is designed to be flexible during resin curing to accommodate dimensional changes, then becomes rigid after curing to provide stable electrical connection. This dynamic property change allows the circuit to absorb stress during curing while maintaining connection integrity in the final product.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexible circuit changes its physical state from flexible to rigid through the curing process. During curing, it remains flexible to accommodate dimensional changes; after curing, it becomes rigid to provide stable electrical connection, thus resolving the contradiction between connection integrity and stress.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If connector assembly is performed after laminate curing, then connection integrity is maintained, but production becomes labor-intensive

Engineering Contradiction:

Improveconnection integrityVSAvoidproduction efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The flexible circuit is pre-integrated into the laminate during the curing process itself, rather than assembling connectors after curing. This preliminary action allows the electrical connection to be established during manufacturing, significantly improving production efficiency while maintaining connection integrity through the flexible-to-rigid transition.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The flexible circuit merges the functions of both the embedded layer and the connector into a single component. This integration allows the electrical connection to be established during laminate formation, eliminating separate post-curing assembly steps and improving productivity while maintaining reliability.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If internal wires or custom detailing are used for external connection, then electrical connection is achieved, but fabrication process is complicated and wrinkles or bulges form

Engineering Contradiction:

Improveelectrical connectionVSAvoidfabrication complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The flexible circuit uses a thin-film structure that can be easily integrated between laminate layers without complicating the fabrication process. This thin-film approach avoids the complexity of internal wires and custom detailing, preventing wrinkles and bulges while achieving reliable electrical connection.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible circuit serves multiple functions: it provides electrical connection, accommodates dimensional changes during curing, and integrates seamlessly with the laminate structure. This multi-functionality eliminates the need for separate internal wires or custom detailing, simplifying fabrication while maintaining connection reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution ensures a reliable and efficient electrical connection while accommodating dimensional changes, reducing fabrication complexity and avoiding wrinkles or bulges, thus enhancing the manufacturing process and integrity of composite components.

Implementation Method 1

the flexible circuit can accommodate some amount of spatial displacement of the connector and the conductive layer relative to one another during curing

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS9793672B2Composite laminate having a flexible circuit bridge and method of manufacture thereof

Publication Date: 2017.10.17 GKN AEROSPACE SERVICES STRUCTURES LLC

AI summary

In a composite component having a laminate body, a conductive layer and a connector can be joined to one another using an intermediate flexible circuit. Among other things, this flexible circuit places the conductive layer and the connector in electrical communication with one another. Furthermore, during the forming process and because of its thinness, the flexible circuit integrates well with the layers of the laminate body and can accommodates some spatial displacement of the connector and conductive material relative to one another.