Patent Application
20180015705
The present disclosure pertains to a structural component forming a power source, a structural component with an electrical transmission device, a method for providing a structural component forming a power source and/or a structural component with an electrical transmission device, an electrical wiring system, and an aircraft component.
Although applicable for any kind of vehicle, the present disclosure and the corresponding underlying problems will be explained in further detail in conjunction with an aircraft component.
Present electrical wiring systems of aircrafts usually comprise a plurality of electrical wires in the form of single cables which are combined in a duct being coupled to a fuselage structure of the aircraft. These wiring systems are used for transmission of electrical power or data transmission. Accordingly, the aircraft data-transmission system is built up essentially of electrical wires that are placed separated from the cabin panels. These wires run in cable bundles, often jointly with power cables. Typically, each wire is solid and round and is supplied with insulation. Several such wires run together in cable bundles. Again, these bundles are fixed into their locations by brackets. The brackets are attached to cabin panels.
It is an idea of the disclosure herein to provide a structural component, in particular structural component for an aircraft, forming a power source and/or with an electrical transmission device and an electrical wiring system which comprise a light weight structure and which can be installed in an easy and flexible manner, respectively.
According to a first aspect of the disclosure herein, a structural component comprises a composite laminate built up of a plurality of layers of carbon fibers, wherein the layers of carbon fibers are oriented in different directions, wherein the carbon fibers are surrounded by a conductive polymer resin, and wherein at least one layer of carbon fibers forms an anode. The structural component further comprises a metal mesh doped with an active cathode material forming a cathode with a flat profile, an ion-transmissive, electrically insulating separator arranged between the anode and the cathode, whereby the composite laminate forming a power source according to the type of a battery device.
Progress made in the field of battery technology can be integrated with a structural component, that is, provided a cathode is present, using the carbon fibers as anodes, electrical power can be provided, inherent in the composite itself, while no separate electrical power cables are needed. The basis for the disclosure herein is a composite laminate of the structural component which is built up of several layers (“plies”) of carbon fibers. The plies are oriented in different directions. The fibers are surrounded by polymer resin. This laminate has structural capabilities. Further, there are modifications made to an ordinary composite laminate. Apart from a layer of carbon fibers, which constitute anodes, and the polymer resin there exists a metal layer, doped with an active cathode material, serving as cathode, and an insulating layer, serving as a separator. Providing the separator is ion-transmissive, all the elements needed for a functioning power source according to the type of a battery are present.
According to one embodiment of the structural component the active cathode material is an electrolyte material, especially a LiMn2O2, a LiCoO2 or a LiFePO4 material. The latter of these materials provides a high security level, high power density, high peak power, high charging current, high cycle stability, high electrical efficiency and a flat voltage profile while charging and uncharging when used as a cathode material for a power source.
According to another embodiment of the structural component, the ion-transmissive separator is a glass fiber layer arranged between the at least one carbon layer forming the anode an the metal mesh, whereby the anodes are effectively separated and electrically insulated from the cathode, while the ion transmission is ensured.
In another embodiment of the structural component at least the carbon fibers of the at least one carbon layer forming the anode are set up with an ion-transmissive, electrically insulating coating forming the separator, whereby the arrangement of a separate layer, e.g. a glass fiber layer, between the anodes formed by the carbon fibers and the cathode formed by the metal layer can be omitted.
In another embodiment, the structural component may be adapted such, that the doped metal layer is set up by a metal mesh, for example a mesh made of copper, whereby the metal layer obtains a light weight structure with a flat profile which is easy to integrate in the composite laminate.
According to a second aspect of the disclosure herein, a structural component comprises a composite laminate built up of a plurality of layers of carbon fibers, wherein the layers of carbon fibers are oriented in different directions and wherein the carbon fibers are surrounded by a conductive polymer resin, wherein the carbon fibers of at least one of the layers comprise an electrically insulating coating, and wherein at least one of the coated carbon fibers extend through its respective layer to form an electrical connection between ends of the layer spaced apart from one another.
Providing the structural component with coated carbon fibers provides a structural device with a functionality as an electrical transmitter, for example an electrical data transmission cable, which itself constitutes an integral part of the composite laminate while the structural component continues to maintain its original function, which is to carry a load. In other words, this constitutes some sort of a multifunctional cable.
In another embodiment of the structural component, the electrically insulating coating of the carbon fibers is ion-transmissive.
According to one embodiment of the structural component stripped end portions of the at least one coated fiber protrude from its respective end of the layer easing the connection with at least one transmission apparatus, or transmitter, or its subset. For example, the transmission apparatus is formed by at least one electrical circuit, which is connectable to at least one power source and/or at least one signal processing device.
The use of a plurality of coated carbon fibers provided for electrical transmission provides redundancy.
Further, these coated carbon fibers can have very small diameters, which is in the order of some microns, for example between 3 and 12 micrometers, or between 5 and 10 micrometers, because the cross section of an ordinary metallic signal cable is reduced drastically. In addition, a rubberized insulation is not used here, nor are the brackets to fasten cables.
A third aspect of the disclosure herein relates to a structural component wherein a composite laminate built up of a plurality of layers of carbon fibers forms a power source to drive electrical signals over at least one electrical connection formed by at least one coated carbon fiber extending through its layer between ends of the layer spaced apart from one another. According to this aspect, the simultaneous integration of a signal transmission capability with the electrical power function provided by a power source constituted by a composite battery is established, as both can be obtained from the same composite laminate. Accordingly, the structural component provides its structural function as well as data transmission and an electrical power source.
A fourth aspect of the disclosure herein relates to a method for providing a structural component, in particular a structural component according the preceding explanations comprising at least the providing of a composite laminate of carbon fiber layers with at least one of which layers containing carbon fibers coated with an electrically insulating coating, the manufacture of the structural component, the stripping of the insulation at opposite ends of at least one coated carbon fiber, connecting the stripped ends of the at least one carbon fiber with a signal processor and/or a power source, transmitting signals or power.
The manufacture of the structural component is eased by a variant of the method, wherein the at least one coated carbon fiber is provided as a carbon fiber yarn or tow coated with an electrically insulating polymer electrolyte.
Another variant of the method provides the use of digital data transmission, which may pass through several cables, whereby the data signals are coded as to which is the sender and for which receiver they are determined. In this manner an electrical redundancy can easily be achieved, if a damage occurs at one location. This redundancy is not necessarily given for today's common single metallic cables.
A further aspect of the disclosure herein relates to an electrical wiring system, extending along a structural component of an aircraft, wherein the electrical wires are formed by coated carbon fibers extending through at least one layer of a composite laminate of the structural component thereby providing a possibility to transport electrical signals along the structural component with little installation effort.
A fourth aspect of the disclosure herein concerns an aircraft, comprising a structural component with the composite laminate comprising a coated carbon fiber layer according to one of the embodiments described above. In particular, the structural component described above comprises a low weight per length due to the integration the electrical wiring in the component. Hence, the structural component may a be integrated in an aircraft, i.e. as a data transmission line or an electrical supply line for electrical functional components arranged within the interior of a fuselage structure of an aircraft, i.e. lighting devices, pumps, or such like.
Generally, according to the present disclosure the structural component and its operating method provide the possibilities, that neither a separate manufacturing of electrical circuitry nor a separate installation of cable bundles is necessary, brackets to fasten cables can as well be avoided as any bonded power/data transmitting tapes or any ink-jet printed circuits. Additionally, no foreign objects are inserted into the sensitive laminate, such as copper cables, fiber optical cables etc., that may deteriorate the structural performance and can be cause for delaminations and cracks. Space requirements as well as weight are reduced, there exists a lower risk that cables or jet-ink circuits are torn apart or damaged during work and maintenance. Further, there is no risk of vibrating cables, and the efforts for inspection and maintenance are reduced significantly. If using digital data transmission with a plurality of fibers, a redundancy is achieved, not available for single metallic cables, which constitutes an safety-improvement.
By integration with a composite power source separate power sources for signals are made unnecessary, while at the same time weight and space are saved and a lowered transmission loss occurs. This holds for a separate power source for steering signal devices made unnecessary as well as additional power cables as power is provided everywhere by integration with a composite power source. Finally there also exists the possibility to connect an arbitrary number of composite power source panels or cells for a tailored amount of voltage.
The disclosure herein will be explained in greater detail with reference to example embodiments depicted in the drawings as appended.
The accompanying drawings are included to provide a further understanding of the present disclosure and are incorporated in and constitute a part of this specification. The drawings illustrate the embodiments of the present disclosure and together with the description serve to explain the principles of the disclosure herein. Other embodiments of the present disclosure and many of the intended advantages of the present disclosure will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale relative to each other. Like reference numerals designate corresponding similar parts.
In the figures, like reference numerals denote like or functionally like components, unless indicated otherwise. Any directional terminology like “top”, “bottom”, “left”, “right”, “above”, “below”, “horizontal”, “vertical”, “back”, “front”, and similar terms are merely used for explanatory purposes and are not intended to delimit the embodiments to the specific arrangements as shown in the drawings.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations may be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.
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The electrical current needed for signals to flow in the cable formed by the carbon fibers 12 is obtained from the composite power source 30. This power source 30 is formed by the layer of carbon fibers 12 building anodes 36 together with the metal layer 32 building the cathode 34. Furthermore, the composite power source 30 provides power to the signal sending and receiving devices 40, 50, as well as to devices operated by their switching not shown here.
More specifically, most or all of the need for “power cables” disappear, when using the concept of composite power source 30. The reason is, that the composite power source 30 provides the power needed wherever the device is. Thus, no cable transmission losses will occur. Moreover, the only cable needed are the signal cables. But also for these applies that no separate signal cables will be necessary any more, since the built-in insulated carbon fibers 12 will serve this purpose.
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To conclude, the disclosure herein provides a structural component 1 comprising a composite laminate 10 with at least one layer 24 containing carbon fibers 12 coated with ion-transmissive and electrically insulating coating 16. To establish a transmission a sending device 40 and a receiving device 50, for example running an identical protocol are provided as well as an arbitrary device with electrical function. The composite laminate 10 shows further features, such as cathode, so as to enable electrical energy storage to operate the sending and receiving devices in collaboration with the coated fibers 12 forming anodes 36.
To operate the corresponding devices, the sending device 40 is connected to a coated carbon fiber 13 intended as a data transmitter at an end portion 22 stripped of coating 16, the receiving device 50 is connected to the carbon fiber 13 in similar manner, the receiving device 50 is further connected to an output device 52, represented by a lamp in
In the foregoing detailed description, various features are grouped together in one or more examples or examples with the purpose of streamlining the disclosure. It is to be understood that the above description is intended to be illustrative, and not restrictive. It is intended to cover all alternatives, modifications and equivalents. Many other examples will be apparent to one skilled in the art upon reviewing the above specification.
The embodiments were chosen and described in order to best explain the principles of the disclosure herein and its practical applications, to thereby enable others skilled in the art to best utilize the disclosure herein and various embodiments with various modifications as are suited to the particular use contemplated. In the appended claims and throughout the specification, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein,” respectively.
While at least one exemplary embodiment of the present invention(s) is disclosed herein, it should be understood that modifications, substitutions and alternatives may be apparent to one of ordinary skill in the art and can be made without departing from the scope of this disclosure. This disclosure is intended to cover any adaptations or variations of the exemplary embodiment(s). In addition, in this disclosure, the terms “comprise” or “comprising” do not exclude other elements or steps, the terms “a”, “an” or “one” do not exclude a plural number, and the term “or” means either or both. Furthermore, characteristics or steps which have been described may also be used in combination with other characteristics or steps and in any order unless the disclosure or context suggests otherwise. This disclosure hereby incorporates by reference the complete disclosure of any patent or application from which it claims benefit or priority.
| Number | Date | Country | Kind |
|---|---|---|---|
| 16 180 005.7 | Jul 2016 | EP | regional |
