Structural composite component and method for configuring a structural composite component

Abstract

A structural composite component, in particular for an aircraft or spacecraft, includes: a lightning strike protection layer; and a composite battery including a cathode layer and a separation layer, wherein the lightning strike protection layer is formed integrated with the cathode layer, and wherein the separation layer is configured for providing acoustic damping, and/or fire barrier, and/or impact resistance to the structural composite component. A method for configuring such a structural composite component; and an aircraft or spacecraft including such a structural composite component are also described.

Claims

1. A structural composite component for an aircraft or spacecraft, comprising: a lightning strike protection layer; and a composite battery comprising a cathode layer and a separation layer, wherein the lightning strike protection layer is formed integrated with the cathode layer, and wherein the separation layer is configured for providing at least one of acoustic damping, a fire barrier, and an impact resistance, wherein the structural composite component is configured as a painted multi-layer skin portion, and wherein the lightning strike protection layer formed integrated with the cathode layer is arranged as an outermost layer of the multi-layer skin portion.

2. The structural composite according to claim 1, wherein the lightning strike protection layer formed integrated with the cathode layer is arranged directly under the paint.

3. The structural composite component according to claim 1, wherein the lightning strike protection layer is configured as the cathode layer, such that the cathode layer forms a single layer.

4. The structural composite component according to claim 3, wherein the lightning strike protection layer configured as the cathode layer is formed as a metallic mesh.

5. The structural composite component according to claim 3, wherein the lightning strike protection layer configured as the cathode layer is formed as a copper mesh.

6. A structural composite component for an aircraft or spacecraft, comprising: a lightning strike protection layer; and a composite battery comprising a cathode layer and a separation layer, wherein the lightning strike protection layer is formed integrated with the cathode layer, and wherein the separation layer is configured for providing at least one of acoustic damping, a fire barrier, and an impact resistance, wherein the lightning strike protection layer is configured as the cathode layer, such that the cathode layer forms a single layer, wherein the composite battery further comprises an anode layer, wherein the separation layer is arranged between the anode layer and the lightning strike protection layer configured as the cathode layer, and wherein the anode layer and the separation layer are integrated into the structural composite component.

7. The structural composite component according to claim 6, wherein the capacity of the composite battery is adapted to a thickness and/or surface of the lightning strike protection layer.

8. The structural composite component according to claim 7, wherein the anode layer comprises a plurality of fiber layers, wherein the number of contacted fiber layers is adapted to the thickness and/or surface of the lightning strike protection layer in terms of capacity of the composite battery.

9. The structural composite component according to claim 8, wherein the anode layer comprises a plurality of carbon fiber layers.

10. The structural composite component according to claim 6, wherein the thickness and/or surface of the lightning strike protection layer is enhanced to be adapted to the capacity of the composite battery.

11. The structural composite component according to claim 10, wherein the anode layer comprises a plurality of fiber layers, wherein the thickness and/or surface of the lightning strike protection layer is enhanced, to more than 0.15 mm, to be adapted to the number of contacted fiber layers in terms of capacity of the composite battery.

12. A method for configuring a structural composite component for an aircraft or spacecraft, the method comprising: providing an anode layer, a separation layer, and a lightning strike protection layer, the separation layer being configured for providing at least one of acoustic damping, fire barrier, and impact resistance; stacking the anode layer, the separation layer, and the lightning strike protection layer; and contacting the anode layer and the lightning strike protection layer to form a composite battery, wherein the lightning strike protection layer is contacted as cathode layer.

13. The method according to claim 12, wherein the stack is formed as a painted multi-layer skin portion, and the lightning strike protection layer contacted as cathode layer is positioned as an outermost layer thereof.

14. The method according to claim 12, wherein stacking the lightning strike protection layer comprises stacking a single metallic mesh, and wherein contacting the lightning strike protection layer comprises contacting the single metallic mesh.

15. The method according to claim 12, wherein stacking the anode layer comprises stacking a plurality of contacted fiber layers, wherein the number of contacted fiber layers is adapted to the thickness and/or surface of the lightning strike protection layer or wherein the thickness and/or surface of the lightning strike protection layer contacted as cathode layer is enhanced to be adapted to the number of contacted fiber layers.

16. An aircraft or spacecraft comprising a structural composite component, according to claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) For a better comprehension of the invention, the following drawings are provided for illustrative and non-limiting purposes, wherein:

(2) FIG. 1A shows a sectional view of a typical composite laminate for an aircraft skin.

(3) FIG. 1B shows an exploded view of typical layers of a lightning strike protection.

(4) FIG. 2 shows a sectional view of a basic build-up of a composite battery cell.

(5) FIG. 3 shows a sectional view of a structural composite component, according to a first embodiment of the present invention.

(6) FIG. 4 shows a sectional view of a structural composite component, according to a second embodiment of the present invention.

(7) FIG. 5 shows an aircraft or spacecraft according to an embodiment of the present invention.

DETAILED DESCRIPTION

(8) Although specific embodiments are 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 invention. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.

(9) FIG. 1A schematically illustrates a sectional view of a typical composite laminate for outer skin.

(10) In FIG. 1, reference sign 101 denotes a laminate comprising an outside paint 105 functioning as surface protection and cosmetic layer. Under the paint 105, a layer for lightning strike protection (LSP) 102 is provided comprising a metal mesh. The LSP 102 is followed by several plies of carbon fiber reinforced polymer (CFRP) 111 with different orientation providing structural strength. For example, a first CFRP ply 111 is oriented +45 and a second CFRP ply 111 is oriented +45. Further CFRP plies 111 may be oriented 90 and 0.

(11) FIG. 1B shows an exploded view of typical layers of an LSP 102.

(12) The LSP 102 itself comprises several layers. An uppermost layer may be configured as resin film 113 functioning as a tool surface, on which the paint 105 may be applied. The resin film 113 comprises a mat/veil carrier 114, which is placed on a metal mesh 112, e. g. configured as expanded copper foil (ECF). The metal mesh 112 has a typical thickness between 0.02 mm and 0.15 mm and provides for electric conductivity.

(13) Underneath the metal mesh 112, another resin film 113 is placed. The bottom layer of the LSP is formed by a paper 110 which serves for placement of the LSP in the panel lamination.

(14) FIG. 2 schematically illustrates a sectional view of a basic build-up of a composite battery cell 103.

(15) The composite battery cell 103 is formed as a stack of layers comprising a cathode layer 104, which is for example configured as a ferritic oxide mesh or as a copper mesh. The cathode layer 104 is arranged in the middle of the stack sandwiched between two separator layers 107 and contacted with a positive contact 108. The separator layers 107 are configured for separating negative and positive parts of the composite battery 103. However, they are configured ion-transmissive, meaning they let charged ion particles transfer through. For example, the separator layers may comprise a glass fiber mesh or glass fiber reinforced plastic, an aramid, a thermoplastic, an elastomer . . . .

(16) On the top and on the bottom of the stack, respectively, an anode layer 106 is arranged and contacted with a negative contact 109. The anode layers 106 comprise for example unidirectional tape or fabric of carbon fiber plies embedded in a solid polymer resin. The polymer resin serves as electrolyte letting ions move, while the carbon fibers function as anode.

(17) FIG. 3 schematically illustrates a sectional view of a structural composite component 1 according to a first embodiment of the present invention.

(18) The structural composite component 1 comprises a metallic lightning strike protection layer 2 and a composite battery 3.

(19) The composite battery 3 comprises an anode layer 6, a separation layer 7 and a cathode layer 4, which are integrated in the stack of the structural composite component 1.

(20) The lightning strike protection layer 2 is configured as the cathode layer 4. Accordingly, the lightning strike protection layer 2 configured as the cathode layer 4 is contacted by a positive contact 8 of the composite battery 3.

(21) Furthermore, the anode layer 6 is contacted with a negative contact 9 of the composite battery 3.

(22) The separation layer 7 is configured for providing acoustic damping, and/or a fire barrier, and/or an impact resistance, and is arranged between the anode layer 6 and the lightning strike protection layer 2 configured as the cathode layer 4.

(23) The lightning strike protection layer 2 configured as the cathode 4 is covered by paint 5 functioning as a surface protection and cosmetic layer. For example, the paint may be configured with logos or the like.

(24) The anode layer 6 is formed by a plurality of fiber layers 6a, 6b, 6c. In the embodiment depicted in FIG. 3, for example three contacted fiber layers 6a, 6b, 6c are provided to form the anode layer 6. However, it will be understood that any suitable number of contacted fiber layers 6a, 6b, . . . 6n may be provided to form the anode layer 6. In particular, the capacity of the composite battery 3 can be adapted to the thickness or surface of the lightning strike protection layer 2 by variation of the number of the contacted fiber layers 6a, 6b, . . . 6n.

(25) Furthermore, additional fiber layers (not shown) which are not contacted may be provided in the stack for structural purposes.

(26) The structural composite component 1 forms a skin portion, in particular for an aircraft or spacecraft 10, configured for providing additional functionalities, such as acoustic damping, and/or a fire barrier, and/or an impact resistance. Thereby, the lightning strike protection layer 2 configured as the cathode layer 4 forms the outermost layer of the skin portion directly under the paint 5.

(27) In the embodiment shown, the lightning strike protection layer 2 configured as the cathode layer 4 is formed as a single layer made of a metallic mesh. Preferably, metallic mesh is configured as a copper mesh. For example, a copper mesh product named Microgrid material by Dexmet Corporation, Wallingford, Conn., USA, may be used. The thickness of the copper mesh is chosen at least according to requirements for LSP and may be chosen bigger, if desired for the cathode function.

(28) FIG. 4 schematically illustrates a sectional view of a structural composite component 1 according to a second embodiment.

(29) The composite component 1 differs from the composite component 1 of FIG. 3 in that the anode layer 6 comprises a plurality of contacted fiber layer 6a, 6b, 6c, 6d, . . . , 6n. In this way, composite battery 3 is configured with a higher capacity.

(30) Accordingly, the thickness of the lightning strike protection layer 2 configured as cathode 4 is enhanced. In the embodiment shown, as an example only, a lightning strike protection layer 2 of enhanced thickness is formed as a double layer of two metal meshes. Therefore, two directly contacted metal meshes are stacked directly upon each other to form the lightning strike protection layer 2 configured as cathode layer 4 with enhanced thickness.

(31) It will be understood that according to another embodiment, a single metal mesh with enhanced thickness may be used instead of a double layer to form the lightning strike protection layer 2.

(32) As explained with regard to FIG. 3, the metal meshes are preferably configured as copper meshes.

(33) FIG. 5 schematically illustrates an aircraft or spacecraft 10.

(34) The aircraft or spacecraft 10 is configured as a commercial aircraft and comprises a fuselage with an outer skin 11. The outer skin 11 is formed as a structural composite component 1, 1 comprising a metallic lightning strike protection layer 2 and a composite battery 3 comprising a cathode layer 4, 4 and a separation layer 7, wherein the metallic lightning strike protection layer 2 is configured as cathode 4 of the composite battery 3, and wherein the separation layer 7 is configured for providing acoustic damping, and/or a fire barrier, and/or an impact resistance, as described with reference to FIG. 3 or FIG. 4.

(35) Although specific embodiments of the invention are 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 exist.

(36) It will be appreciated that the exemplary embodiments are examples only and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing at least one exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims and their legal equivalents. Generally, this application is intended to cover any adaptations or variations of the specific embodiments discussed herein.

(37) 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 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.