Metalized fiber mat

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Solution Overview

Problem

Aerospace vehicles constructed from composite plastic materials lack the electromagnetic shielding capabilities inherent in metallic constructions, necessitating the development of lightweight, corrosion-resistant materials to manage radiofrequency (RF) energy and enhance survivability against electromagnetic interference (EMI).

Innovation Solution

The use of metalized fiber mats or sheets with non-woven fibers coated using a vacuum deposition technique, featuring a conductive metal layer and a corrosion-resistant metal layer providing 360-degree coverage, which can be integrated into aircraft structures to provide EMI shielding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If composite plastic materials are used for aerospace vehicles, then weight is reduced, but electromagnetic shielding capability is lost

Engineering Contradiction:

Improvevehicle weightVSAvoidelectromagnetic interference shielding

Core Design Contradiction:

Weight of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent applies composite materials by combining non-woven fibers with multiple metal coatings (conductive metal layer and corrosion-resistant metal layer) to create a fiber mat that provides both electromagnetic shielding and corrosion resistance while maintaining lightweight properties suitable for aerospace applications

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies local quality by providing different metal coatings on the fiber surfaces - a conductive metal layer for electromagnetic shielding and a corrosion-resistant metal layer for environmental protection - thereby giving different functional properties to different aspects of the same material structure

Inventive Principle:

Principle #3Local quality

2Object-affected harmful factors

If metal coatings are applied to fibers for EMI shielding, then shielding capability is improved, but corrosion resistance deteriorates

Engineering Contradiction:

Improveelectromagnetic interference shieldingVSAvoidcorrosion resistance

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent uses composite materials by layering a conductive metal coating for EMI shielding with a corrosion-resistant metal coating, creating a composite structure where each layer performs its specific function - the conductive layer provides electromagnetic shielding while the corrosion-resistant layer protects against environmental degradation

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Inventive Principle:

Principle #3Local quality

3Manufacturing precision

If vacuum deposition technique is used for metal coating, then coating uniformity is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvecoating uniformityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical coating methods with vacuum deposition technique, which uses physical vapor deposition processes to achieve uniform metal coating on fiber surfaces without complex mechanical application systems, thereby improving coating uniformity while managing manufacturing complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 metalized fiber mats offer effective EMI shielding with reduced surface resistance and increased corrosion resistance, enhancing the survivability of aerospace vehicles while maintaining a lightweight and conductive properties, thus addressing the shielding deficiencies in composite plastic materials.

Implementation Method 1

a conductive metal coating of a uniform thickness on said fibers produced by a vacuum deposition technique

Methodology Applied

Scientific EffectVacuum deposition: Physical Vapour Deposition

Implementation Method 2

a corrosion resistant metal coating of a uniform thickness, said corrosion resistant metal having 360 degree coverage over said conductive metal coating

Methodology Applied

Scientific EffectCorrosion resistance:

Data Source

PatentUS11076514B1Metalized fiber mat

Publication Date: 2021.07.27 TRITON SYSTEMS INC

AI summary

Conductive, lightweight, corrosion-resistant fiber mats are described herein. More particularly a metalized fiber mat of non-woven fibers has a conductive metal coating of a uniform thickness and a corrosion-resistant metal coating of a uniform thickness. Methods of producing such fiber mats are also provided.