Hybrid Braided Composite Parts for Static Dissipation

Solution Overview

Problem

Fiber-reinforced composite parts, such as filament-wound fiberglass, face limitations in versatility due to restricted interlacements and the need for additional static charge dissipation methods, which complicates the fabrication process and requires separate adherence of conductive materials.

Innovation Solution

The method involves braiding carbon and fiberglass fibers together to form a hybrid composite part, allowing for static charge dissipation without additional adherence, enhancing strength and production efficiency by integrating conductive carbon fibers within the weave, which can be impregnated with resin to harden into a composite part.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If filament winding is used to fabricate fiberglass parts, then production rates are maintained, but versatility is limited due to restricted interlacements and separate adherence of conductive materials is required

Engineering Contradiction:

Improveversatility of composite partsVSAvoidcomplexity of fabrication process

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges the structural fiberglass fibers with conductive carbon fibers into a single hybrid braided composite structure. This eliminates the separate step of adhering conductive materials to the tube surface, as the conductive function is integrated directly into the composite material itself through the hybrid fiber architecture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite materials by creating a hybrid braid combining chemically distinct fiberglass and carbon fibers. This composite approach allows the material to simultaneously provide structural integrity from the fiberglass and static dissipation properties from the conductive carbon fibers, enhancing versatility without complicating the fabrication process.

Inventive Principle:

Principle #40Composite materials

2Reliability

If copper mesh is adhered to fiberglass tubes for static charge dissipation, then safety is enhanced, but fabrication complexity increases due to additional adherence steps

Engineering Contradiction:

Improvestatic charge dissipationVSAvoidcomplexity of fabrication process

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the structural fiberglass fibers with conductive carbon fibers into a single hybrid braided composite structure. This eliminates the separate step of adhering conductive materials to the tube surface, as the conductive function is integrated directly into the composite material itself through the hybrid fiber architecture.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The hybrid braided composite structure provides self-service by inherently possessing both structural and static dissipation functions. The conductive carbon fibers within the braid automatically perform the static charge dissipation function without requiring external adherence of separate conductive layers, simplifying the fabrication process.

Inventive Principle:

Principle #25Self-service

3Strength

If hybrid braiding of carbon and fiberglass fibers is implemented, then static charge dissipation is integrated and strength is enhanced, but manufacturing complexity increases

Engineering Contradiction:

Improvestrength of composite partsVSAvoidcomplexity of braiding process

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent employs composite materials by creating a hybrid braid combining chemically distinct fiberglass and carbon fibers. This composite approach allows the material to simultaneously provide structural integrity from the fiberglass and static dissipation properties from the conductive carbon fibers, enhancing versatility without complicating the fabrication process.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The hybrid braided composite achieves multi-functionality by integrating structural support and static charge dissipation into a single material system. The same hybrid fiber braid that provides mechanical strength also provides conductive pathways for static dissipation, eliminating the need for separate functional layers or adherence steps.

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 approach eliminates the need for separate static dissipation elements, enhances the strength and production rates of composite parts, and maintains the structural integrity of the braided composite parts by using chemically distinct fibers that can conduct static charges effectively.

Implementation Method 1

The carbon fibers, because they are conductive, are capable of dissipating static charges

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

impregnating the weave with a resin, and hardening the resin within the weave to form a hybrid composite part

Methodology Applied

Scientific EffectPolymerization/Hardening: Photopolymerisation

Data Source

PatentUS11235537B2Hybrid braided composite parts

Publication Date: 2022.02.01 THE BOEING CO

AI summary

Systems and methods are provided for fabricating a hybrid composite part. A method includes braiding a first set of fibers to form a weave having a closed cross-sectional shape, braiding a second set of fibers into the weave that are chemically distinct from the first set of fibers, impregnating the weave with a resin, and hardening the resin within the weave to form a hybrid composite part.