Integrated Surface Protection System for Composite Structures

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Solution Overview

Problem

Current surface protection systems for composite structures, such as aircraft, require multiple layers for lightning strike protection, UV protection, and primer adhesion, which increases design weight, manufacturing complexity, and thermal stress, while also complicating the drilling process for fasteners.

Innovation Solution

An integrated surface protection system featuring a single layer with an electrically conductive network and fiber reinforcement material, which provides simultaneous lightning strike protection, UV protection, and a smooth surface for primer adhesion, reducing thermal stress and manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If multiple individual layers are used for lightning strike protection, UV protection, and primer adhesion, then each protective function is provided, but design weight increases and manufacturing complexity increases

Engineering Contradiction:

Improveprotective functionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines multiple protective layers (lightning strike protection, UV protection, primer adhesion layers) into a single integrated layer containing an electrically conductive network and fiber reinforcement material, thereby reducing the number of layers and simplifying manufacturing processes

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The single integrated layer performs multiple functions simultaneously: it provides lightning strike protection through the electrically conductive network, UV protection through appropriate material selection, and primer adhesion through a smooth surface finish, making the layer universal for multiple protective purposes

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If multiple individual layers are used for lightning strike protection, UV protection, and primer adhesion, then each protective function is provided, but design weight increases

Engineering Contradiction:

Improveprotective functionVSAvoiddesign weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The patent merges multiple separate protective layers into one integrated layer, directly reducing the total weight by eliminating redundant materials and interfaces between layers while maintaining all required protective functions

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If multiple individual layers are used for lightning strike protection, UV protection, and primer adhesion, then each protective function is provided, but thermal stress increases

Engineering Contradiction:

Improveprotective functionVSAvoidthermal stress

Core Design Contradiction:

ReliabilityVSStress or pressure

Solution Approach 1:

The patent combines multiple layers into a single integrated structure with uniform thermal expansion properties, eliminating thermal stress issues that arise from interfaces between layers with different thermal expansion coefficients

Inventive Principle:

Principle #5Merging (Combining)

4Reliability

If multiple individual layers are used for lightning strike protection, UV protection, and primer adhesion, then each protective function is provided, but the drilling process for fasteners is complicated

Engineering Contradiction:

Improveprotective functionVSAvoiddrilling process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent integrates all protective functions into a single layer with uniform mechanical properties, allowing fasteners to be drilled through one homogeneous layer rather than navigating multiple layers with different properties and interfaces

Inventive Principle:

Principle #5Merging (Combining)

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 integrated system enhances durability, reduces manufacturing costs, and simplifies processing by combining multiple functionalities into a single layer, improving structural integrity and environmental durability while maintaining paint layer integrity.

Implementation Method 1

The plurality of electrically conductive elements are electrically connected to one another to form an electrically conductive network

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

The single layer includes an electrically conductive network and a fiber reinforcement material

Methodology Applied

Scientific EffectFiber reinforcement: Composite Materials

Implementation Method 3

The matrix material binds and encapsulates the plurality of electrically conductive elements and the fiber reinforcement material

Methodology Applied

Scientific EffectEncapsulation: Binder

Data Source

PatentUS11220351B2Integrated surface protection system, composite structure, and method for protecting the same

Publication Date: 2022.01.11 THE BOEING CO

AI summary

An integrated surface protection system includes a single layer comprising an electrically conductive network and a fiber reinforcement material.