STRUCTURAL COMPOSITE COMPONENT AND METHOD FOR CONFIGURING A STRUCTURAL COMPOSITE COMPONENT

Abstract

A structural composite component, in particular for an aircraft or spacecraft, has a lightning strike protection layer, and a composite battery comprising a cathode layer, wherein the lighting strike protection layer is formed integrated with the cathode layer.

Claims

1. A structural composite component comprising: a lightning strike protection layer; and a composite battery comprising a cathode layer, wherein the lighting strike protection layer is formed integrated with the cathode layer.

2. The structural composite component of claim 1, wherein the structural composite component is configured as a painted multi-layer skin portion.

3. The structural composite component of claim 2, wherein the lighting strike protection layer formed integrated with the cathode layer is arranged as an outermost layer of the multi-layer skin portion.

4. The structural composite component of claim 3, wherein the lighting strike protection layer formed integrated with the cathode layer is arranged directly under the paint.

5. The structural composite component of claim 1, wherein the lighting strike protection layer is configured as the cathode layer.

6. The structural composite component of claim 1, wherein the lighting strike protection layer is configured such that it forms a single layer.

7. The structural composite component of claim 5, wherein the lighting strike protection layer configured as the cathode layer is formed as a metallic mesh.

8. The structural composite component of claim 7, wherein the lighting strike protection layer configured as the cathode layer is formed as a copper mesh.

9. The structural composite component of claim 5, wherein the cathode layer comprises a composite battery, which further comprises an anode layer and a separation layer arranged between the anode layer and the lighting strike protection layer configured as the cathode layer, and wherein the anode layer and the separation layer are integrated into the structural composite component.

10. The structural composite component of claim 9, wherein the capacity of the composite battery is adapted to at least one of the thickness and the surface of the lightning strike protection layer.

11. The structural composite component of claim 10, wherein the anode layer comprises a plurality of fiber layers wherein the number of contacted fiber layers is adapted to at least one of the thickness and the surface of the lightning strike protection layer in terms of capacity of the composite battery.

12. The structural composite component of claim 10, wherein at least one of the thickness and the surface of the lightning strike protection layer is enhanced to be adapted to the capacity of the composite battery.

13. The structural composite component of claim 10, wherein the anode layer comprises a plurality of carbon fiber layers.

14. The structural composite component of claim 13, wherein the anode layer comprises a plurality of fiber layers, wherein at least one of the thickness and the surface of the lightning strike protection layer is enhanced to be adapted to the number of contacted fiber layers in terms of capacity of the composite battery.

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

16. The structural composite component of claim 12, wherein the thickness of the lightning strike protection layer is enhanced to more than 0.15 mm.

17. A method for configuring a structural composite component, the method comprising: stacking an anode layer, a separation layer and a 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 a cathode layer.

18. The method of claim 17, wherein the stack is formed as a painted multi-layer skin portion and the lightning strike protection layer contacted as the cathode layer is positioned as an outermost layer thereof.

19. The method of claim 18, wherein the lightning strike protection layer contacted as the cathode layer is positioned directly under the paint.

20. The method of claim 17, 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.

21. The method of claim 17, wherein stacking the anode layer comprises stacking a plurality of contacted fiber layers, wherein the number of contacted fiber layers is adapted to at least one of the thickness and the surface of the lightning strike protection layer.

22. The method of claim 17, wherein stacking the anode layer comprises stacking a plurality of contacted fiber layers, wherein at least one of the thickness and the surface of the lightning strike protection layer contacted as the cathode layer is enhanced to be adapted to the number of contacted fiber layers.

23. The method of claim 21, wherein stacking the anode layer comprises stacking a plurality of contacted carbon fiber layers.

24. The method of claim 22, wherein stacking the anode layer comprises stacking a plurality of contacted carbon fiber layers.

25. An aircraft or spacecraft comprising a structural composite component, the structural composite component comprising a lightning strike protection layer; and a composite battery comprising a cathode layer, wherein the lighting strike protection layer is formed integrated with the cathode layer.

26. Aircraft or spacecraft comprising a structural composite component, the structural composite component formed by a method comprising: stacking an anode layer, a separation layer and a 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.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The invention will be explained in greater detail with reference to exemplary embodiments depicted in the drawings as appended.

[0032] The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate the embodiments of the present invention and together with the description serve to explain the principles of the invention. Other embodiments of the present invention and many of the intended advantages of the present invention will be readily appreciated as they become better understood by reference to the following detailed description. The elements of the drawings are not necessarily in scale relative to each other. In the figures, like reference numerals denote like or functionally like components, unless indicated otherwise.

[0033] FIG. 1A schematically illustrates a sectional view of a typical composite laminate for an aircraft skin.

[0034] FIG. 1B shows an exploded view of typical layers of an LSP.

[0035] FIG. 2 schematically illustrates a sectional view of a basic build-up of a composite battery cell.

[0036] FIG. 3 schematically illustrates a sectional view of a structural composite component.

[0037] FIG. 4 schematically illustrates a sectional view of a structural composite component according to another embodiment.

[0038] FIG. 5 illustrates an aircraft or spacecraft.

[0039] 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.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0040] FIG. 1A schematically illustrates a sectional view of a typical composite laminate for outer skin of an aircraft, for example.

[0041] In FIG. 1, reference sign 101 denotes a laminate comprising an outside paint 105 functioning as a 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 orientations 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°.

[0042] FIG. 1B shows an exploded view of typical layers of an LSP 102.

[0043] 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.

[0044] 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.

[0045] FIG. 2 schematically illustrates a sectional view of a basic build-up of a composite battery cell 103.

[0046] 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.

[0047] 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 an anode.

[0048] FIG. 3 schematically illustrates a sectional view of a structural composite component 1.

[0049] The structural composite component 1 comprises a metallic lightning strike protection layer 2 and a composite battery 3.

[0050] 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.

[0051] 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.

[0052] Furthermore, the anode layer 6 is contacted with a negative contact 9 of the composite battery 3.

[0053] The lightning strike protection layer 2 configured as the cathode 4 is covered by a paint 5 functioning as a surface protection and cosmetic layer. For example, the paint may be configured with logos or the like.

[0054] 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.

[0055] Furthermore, additional fiber layers (not shown) which are not contacted may be provided in the stack for structural purposes.

[0056] The structural composite component 1 forms a skin portion, in particular for an aircraft or spacecraft 10. 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.

[0057] 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. The metallic mesh can be 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 the LSP and may be chosen bigger, if desired for the cathode function.

[0058] FIG. 4 schematically illustrates a sectional view of a structural composite component 1′ according to another embodiment.

[0059] The composite component 1′ differs from the composite component 1 of FIG. 3 in that the anode layer comprises a plurality of contacted fiber layers 6a, 6b, 6c, 6d, . . . , 6n. In this way, composite battery is configured with a higher capacity.

[0060] Accordingly, the thickness of the lightning strike protection layer 2′ configured as the 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 the cathode layer 4′ with enhanced thickness.

[0061] 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′.

[0062] As explained with regard to FIG. 3, the metal meshes can be configured configured as copper meshes.

[0063] FIG. 5 schematically illustrates an aircraft or spacecraft 10.

[0064] 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 comprising a metallic lightning strike protection layer 2 and a composite battery 3 wherein the metallic lightning strike protection layer 2 is configured as cathode 4 of the composite battery 3, as described with reference to FIG. 3 or 4.

[0065] 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.

[0066] 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.

[0067] 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.