Structural component forming an electrical power source, structural component with an electrical transmission device, method for providing a structural component forming an electrical power source and/or an electrical transmission device, electrical wiring system and aircraft component
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Solution Overview
Problem
Current aircraft electrical wiring systems are heavy, cumbersome, and require separate installation and maintenance, lacking flexibility and redundancy, which increases weight, space requirements, and risk of damage during maintenance.
Innovation Solution
A structural component comprising a composite laminate of carbon fibres oriented in different directions, coated with an electrically insulating and conductive polymer resin, allowing for integrated electrical transmission and power sourcing within the structural component, eliminating the need for separate cables and brackets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional separate cables and brackets are used for electrical wiring, then electrical transmission function is achieved, but weight and space requirements increase
Solution Approach 1:
The patent combines the electrical transmission function with the structural component by integrating conductive polymer resin and coated carbon fibres directly into the composite laminate. This merging eliminates the need for separate cables and brackets, reducing both weight and device complexity while maintaining electrical transmission capability.
Solution Approach 2:
The structural component is designed to serve multiple functions simultaneously: it provides structural support, electrical transmission, and electrical insulation. The composite laminate with conductive polymer resin and coated carbon fibres creates a multifunctional system that replaces traditional separate wiring components.
2Ease of operation
If traditional wiring systems with separate cables are used, then electrical transmission is achieved, but flexibility and ease of installation are reduced
Solution Approach 1:
By integrating the electrical transmission function directly into the structural component during manufacturing, the patent eliminates the need for separate cable installation. The conductive polymer resin and coated carbon fibres are incorporated into the composite laminate, allowing the component to be installed as a single unit, thereby improving ease of installation and reducing flexibility issues associated with separate cables.
3Weight of moving object
If coated carbon fibres are used for electrical transmission, then weight is reduced and redundancy is provided, but manufacturing complexity increases
Solution Approach 1:
The patent uses composite materials consisting of carbon fibres coated with electrically insulating material, embedded in a conductive polymer resin matrix. This composite structure reduces weight compared to traditional metallic cables while providing redundancy through the distributed fibre network. The coating process, while adding manufacturing steps, creates a lightweight yet functional transmission system.
4Ease of repair
If separate power sources and cables are used, then electrical power transmission is achieved, but maintenance efforts and risk of damage increase
Solution Approach 1:
By integrating the electrical transmission function into the structural component itself, the patent eliminates separate power sources and cables that would require maintenance. The coated carbon fibres embedded in the composite laminate create a durable, maintenance-free system that reduces the risk of damage during maintenance operations, as there are no separate components to handle or repair.
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 solution provides a lightweight, flexible, and redundant electrical wiring system that integrates data transmission and power sourcing, reducing weight, space, and maintenance efforts while enhancing safety by eliminating the need for separate power sources and cables.
Implementation Method 1
the carbon fibres of at least one of the layers comprise an electrically insulating coating
Implementation Method 2
the electrically insulating coating of the carbon fibres is ion-transmissive
Implementation Method 3
the carbon fibres are surrounded by a conductive polymer resin
Data Source
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Figure 8
AI summary
A structural component (1) includes a composite laminate (10) built up of a plurality of layers (24) of carbon fibres (12), wherein the layers (24) of carbon fibres (12) are oriented in different directions and wherein the carbon fibres (12) are surrounded by a conductive polymer resin (14). The carbon fibres (12) of at least one of the layers (24) comprise an electrically insulating coating (16), and wherein at least one of the coated carbon fibres (12) extend through its respective layer (24) to form an electrical connection between ends (26) of the layer (24) spaced apart from one another. With an ion-transmissive insulation coating (16) the carbon fibres (12) form anodes such that, together with a metal layer (32) provided with the composite laminate (10) forming an cathode, the structural is enabled to additionally form an integrated composite power source (30).