Composite structures with embedded electrical grids

Patent metadata

Field	Value
Publication number	US-12017435-B2
Application number	US-202318099068-A
Country	US
Kind code	B2
Filing date	Jan 19, 2023
Priority date	Feb 21, 2020
Publication date	Jun 25, 2024
Grant date	Jun 25, 2024

Abstract

A composite structure of a cargo body and a method of making the same are disclosed. The composite structure includes at least one electrical grid embedded within fiber-reinforced polymer (FRP) layers. The embedded electrical grid includes a plurality of conductive fibers and a plurality of insulating fibers integrated into a polymer matrix of the FRP layers. The embedded electrical grid may be used for power distribution, structural strengthening and stiffness, and/or puncture detection.

First claim

What is claimed is:

1. A laminated composite structure of a cargo body, the composite structure comprising:
a core layer;
an outer fiber-reinforced polymer layer coupled to the core layer;
an inner fiber-reinforced polymer layer coupled to the core layer; and
at least one electrical grid embedded within one or more of the outer and inner fiber-reinforced polymer layers, wherein the at least one electrical grid includes:
a first plurality of conductive fibers;
a second plurality of conductive fibers perpendicular to the first plurality of conductive fibers;
wherein the at least one electrical grid is embedded within one of the outer and inner fiber-reinforced polymer layers on one side of the core layer, the electrical grid further including a plurality of intermediate insulating fibers sandwiched between the first plurality of conductive fibers and the second plurality of conductive fibers;
wherein the composite structure is a sidewall of a refrigerated trailer, and further comprising a sensor coupled to at least two of a first plurality of subsets of the first plurality of conductive fibers or at least two of a second plurality of subsets of the second plurality of conductive fibers, wherein the sensor is at least one of a temperature sensor, a moisture sensor, a GPS sensor, a load sensor, and an accelerometer, the sensor configured to communicate a signal indicative of a state of the refrigerated trailer.

2. The composite structure of claim 1 , wherein:
the plurality of intermediate insulating fibers form a mat;
the first plurality of conductive fibers are stitched into one side of the mat; and
the second plurality of conductive fibers are stitched into another side of the mat.

3. The composite structure of claim 1 , wherein the first plurality of conductive fibers and the second plurality of conductive fibers provide structural reinforcement of the composite structure.

4. The composite structure of claim 1 , wherein the plurality of intermediate insulating fibers are glass.

5. The composite structure of claim 1 , wherein a polymer matrix from a corresponding one of the outer and inner fiber-reinforced polymer layers is integrated into the at least one electrical grid.

6. The composite structure of claim 1 , wherein:
the first plurality of subsets is powered in an alternating manner; and
the second plurality of subsets is powered in an alternating manner.

7. The composite structure of claim 1 , wherein the trailer includes a power source in electrical communication with the at least one electrical grid.

8. The composite structure of claim 7 , wherein the trailer includes a control system programmed to detect a break in the at least one electrical grid.

9. The composite structure of claim 8 , wherein the control system is programmed to identify a location of the break.

10. The composite structure of claim 1 , wherein the sensor is a temperature sensor.

11. A laminated composite structure of a cargo body, the composite structure comprising:
a core layer;
an outer fiber-reinforced polymer layer coupled to the core layer;
an inner fiber-reinforced polymer layer coupled to the core layer; and
at least one electrical grid embedded within one or more of the outer and inner fiber-reinforced polymer layers, wherein the at least one electrical grid includes:
a first plurality of conductive fibers;
a second plurality of conductive fibers perpendicular to the first plurality of conductive fibers;
wherein the at least one electrical grid is embedded within one of the outer and inner fiber-reinforced polymer layers on one side of the core layer, the electrical grid further including a plurality of intermediate insulating fibers extending between at least one of adjacent fibers of the first plurality of conductive fibers and adjacent fibers of the second plurality of conductive fibers.

Assignees

• Wabash National Lp

Inventors

• Wylezinski Andrzej

Classifications

• B32B7/025

  Electric or magnetic properties · CPC title

• B32B2457/00

  Electrical equipment · CPC title

• B32B2307/20

  having particular electrical or magnetic properties, e.g. piezoelectric · CPC title

• B32B2262/106

  Carbon fibres, e.g. graphite fibres · CPC title

• B32B2260/021

  Fibrous or filamentary layer · CPC title