Composite layers with exposed reinforcement

Patent metadata

Field	Value
Publication number	US-10046528-B2
Application number	US-201213400334-A
Country	US
Kind code	B2
Filing date	Feb 20, 2012
Priority date	Feb 20, 2012
Publication date	Aug 14, 2018
Grant date	Aug 14, 2018

Abstract

A composite structure comprising a matrix and a reinforcement. The matrix comprises a substantially nonconductive material. The reinforcement comprises a conductive material. The reinforcement is located within the matrix to form a composite layer. A portion of the reinforcement is exposed at a surface of the composite layer such that electrical conductivity of the composite layer is increased in a direction substantially perpendicular to the composite layer.

First claim

What is claimed is:

1. A skin panel for an aerospace vehicle comprising:
a first composite layer of the skin panel, the first composite layer comprising:
a first matrix comprising a substantially nonconductive material;
a first reinforcement comprising a conductive material, wherein the first reinforcement is transversely located within the first matrix perpendicular to a z-axis for the first composite layer to form the first composite layer in the skin panel in which a first portion of the first reinforcement is exposed at a first surface of the first composite layer such that a first electrical conductivity of the first composite layer is increased in a direction substantially perpendicular to the first composite layer; and

a second composite layer of the skin panel, the second composite layer comprising
a second matrix;
a second reinforcement transversely located within the second matrix perpendicular to a z-axis for the second composite layer, wherein the second matrix and the second reinforcement form the second composite layer in which a second portion of the second reinforcement is exposed at a second surface of the second composite layer such that a second electrical conductivity of the second composite layer is increased in a direction substantially perpendicular to the second composite layer;

wherein the first portion of the first reinforcement exposed at the first surface of the first composite layer contacts the second portion of the second reinforcement exposed at the second surface of the second composite layer when the second composite layer and the first composite layer are positioned relative to each other to form the skin panel; and
wherein contact between the first portion of the first reinforcement and the second portion of the second reinforcement electrically connects the first composite layer and the second composite layer to provide a desired level of electrical conductivity in a direction substantially parallel to a z-axis for the skin panel;
wherein the first reinforcement and the second reinforcement each comprise a plurality of conductive fibers; and
wherein the first portion and the second portion each comprise exposed parts of some the plurality of conductive fibers through which a number of electrical currents is allowed to flow into and out of a composite layer.

2. The skin panel of claim 1 , wherein the first portion of the first reinforcement is exposed at a selected portion of the first surface such that the desired level of electrical conductivity of the composite layer is increased in the direction substantially perpendicular to the composite layer at the selected portion of a surface.

3. The skin panel of claim 1 , wherein the first composite layer and the second composite layer are layers in a plurality of composite layers that form the skin panel.

4. The skin panel of claim 3 , wherein an electromagnetic event that occurs in an environment around the plurality of composite layers induces electrical energy in the plurality of composite layers and wherein the plurality of composite layers conducts the electrical energy between the composite layers in the plurality of composite layers in the direction substantially parallel to the z-axis for the plurality of composite layers.

5. The skin panel of claim 3 , wherein the skin panel comprising the plurality of composite layers is a carbon fiber reinforced plastic.

6. The skin panel of claim 1 , wherein the first portion of the first reinforcement embedded in the first matrix is exposed at the first surface of the composite layer using at least one of a mechanical process, a chemical process, a laser surface ablation process, an etching process, a threading process, a stitching process, an abrasion process, a sanding process, and a raking process.

7. A skin panel for an aerospace vehicle comprising:
a plurality of composite layers in which a first composite layer in the plurality of composite layers comprises:
a first matrix comprising a substantially nonconductive material; and
a first reinforcement comprising a conductive material and located within the first matrix in which a first portion of the first reinforcement is transversely located within the first matrix perpendicular to a z-axis for the first composite layer and exposed at a first surface of the first composite layer such that a first electrical conductivity of the first composite layer is increased in a direction substantially perpendicular to the first composite layer, wherein the first portion of the first reinforcement exposed at a surface of the first composite layer electrically connects the first composite layer to another composite layer in the plurality of composite layers such that a composite structure has a desired level of electrical conductivity in a direction substantially parallel to a z-axis for the composite structure;
wherein the first reinforcement comprises a plurality of conductive fibers; and
wherein the first portion comprises exposed parts of some of the plurality of conductive fibers through which a number of electrical currents is allowed to flow into and out of the composite layer.

8. The skin panel of claim 7 , wherein the skin panel comprising the plurality of composite layers is carbon fiber reinforced plastic.

9. A method for conducting electrical energy using a composite structure, the method comprising:
operating an object comprising the composite structure in which the electrical energy is induced in the composite structure in response to an electromagnetic event that occurs during operation of the object, wherein the composite structure comprises a plurality of composite layers in which a composite layer in the plurality of composite layers comprises:
a matrix comprising a substantially nonconductive material; and
a reinforcement comprising a conductive material and located within the matrix in which a portion of the reinforcement is exposed at a surface of the composite layer; and
conducting the electrical energy induced in the composite structure in response to the electromagnetic event within the composite structure using the portion of the reinforcement exposed at the surface of the composite layer in the plurality of composite layers such that electrical conductivity of the composite structure is increased in a direction substantially parallel to a z-axis for the composite structure;

wherein the reinforcement comprises a plurality of conductive fibers and the portion comprises exposed parts of some of the plurality of conductive fibers through which a number of electrical currents is allowed to flow into and out of the composite layer.

10. The method of claim 9 , wherein the step of conducting the electrical energy induced in the composite structure in response to the electromagnetic event within the composite structure using the portion of the reinforcement exposed at the surface of the composite layer in the plurality of composite layers such that an electrical conductivity of the composite structure is increased in the direction substantially parallel to the z-axis for the composite structure comprises:
conducting the electrical energy induced in the composite structure in response to the electromagnetic event within the composite structure such that the electrical conductivity of the composite structure is increased in the direction substantially parallel to the z-axis for the composite structure, wherein the portion of the reinforcement exposed at the surface of the composite layer electrically connects the composite layer to another composite layer in the plurality of composite layers such that the composite structure has a desired level of electrical conductivity in the direction substantially parallel to the z-ax

Assignees

• Gaw Kevin Obrien
• Boeing Co

Inventors

• Gaw Kevin O'Brien

Classifications

• B29C70/882 Primary

  partly or totally electrically conductive, e.g. for EMI shielding (conductive floors or floor coverings H05F3/025; EMI shielding in general H05K9/00) · CPC title

• B29C70/64

  the filler influencing the surface characteristics of the material, e.g. by concentrating near the surface or by incorporating in the surface by force · CPC title

• B29K2995/0005

  Conductive · CPC title

• Y10T156/10

  Methods of surface bonding and/or assembly therefor · CPC title

• B29C70/545

  Perforating, cutting or machining during or after moulding · CPC title