Polyether Sulfone Foil Mediator for Cold Gas Sprayed Conductive Layers
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Solution Overview
Problem
Fiber reinforced polymer components, commonly used in rotary wing aircraft, face challenges with poor adherence of metal sprays during cold gas spraying, leading to inadequate electrical conductivity and increased vulnerability to lightning strikes due to high electrical resistance, which necessitates a reliable and high-quality metallization method.
Innovation Solution
A method involving the use of a polyether sulfone foil as an intermediate layer on the fiber reinforced polymer component, allowing for high-quality cold gas spraying of electrically conductive particles, such as copper, aluminum, or silver, to create a reliable and lightweight electrically conductive layer without damaging the underlying material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cold gas spraying is used to apply metallic circuit paths on fiber reinforced polymer components, then electrical conductivity is improved, but adherence quality deteriorates because metal sprays damage the fibers or resin material
Solution Approach 1:
A polyether sulfone foil is introduced as an intermediate layer between the fiber reinforced polymer component and the metallic circuit paths. This intermediary layer provides a suitable substrate for cold gas spraying, enabling high-quality adherence of metal particles without directly contacting and damaging the fragile fiber reinforced polymer surface. The polyether sulfone foil acts as a mediator that transfers the mechanical stress and provides a stable base for the metallic coating.
Solution Approach 2:
The polyether sulfone foil is applied to the fiber reinforced polymer component before the cold gas spraying process. This preliminary action prepares the surface by creating a suitable substrate that enhances subsequent metal particle adherence. The foil is positioned and secured on the component surface prior to spraying, ensuring that the metallic circuit paths will adhere properly to the foil rather than directly to the damaged fiber reinforced polymer.
2Weight of moving object
If fiber reinforced polymer components are used in rotary wing aircraft, then weight is reduced, but electrical resistance increases leading to higher vulnerability to lightning strikes
Solution Approach 1:
The solution creates a composite structure combining fiber reinforced polymer (for weight reduction), polyether sulfone foil (as intermediate layer), and metallic circuit paths (for electrical conductivity). This multi-material composite approach allows the aircraft to benefit from the lightweight properties of fiber reinforced polymer while adding the necessary electrical conductivity through the metal layers, thereby reducing lightning strike vulnerability without sacrificing weight advantages.
Solution Approach 2:
The metallic circuit paths are applied locally to specific regions of the fiber reinforced polymer component where electrical conductivity is needed, rather than making the entire component metallic. This localized approach provides sufficient electrical protection for lightning strike vulnerability while maintaining the overall lightweight characteristic of the fiber reinforced polymer structure.
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 enables effective protection against lightning direct and indirect effects while facilitating integrated electrical routing and equipment provision, ensuring a robust and efficient metallization process.
Implementation Method 1
performing a cold gas spraying process for spraying electrically conductive particles onto the polyether sulfone foil in order to create the electrically conductive layer
Data Source
AI summary
A structural arrangement comprising a fiber reinforced polymer component, a cold gas spraying electrically conductive layer, and a polyether sulfone foil arranged on the fiber reinforced polymer component, at least in a region between the fiber reinforced polymer component and the cold gas sprayed electrically conductive layer.