Low density lightning strike protection for use in airplanes

• US 8,962,130 B2
• Filed: 03/09/2007
• Issued: 02/24/2015
• Est. Priority Date: 03/10/2006
• Status: Active Grant

• Current Assignee: Goodrich Corporation (Rtx Corporation), ROHR Incorporated (Rtx Corporation)
• Original Assignee: ROHR Incorporated (Rtx Corporation)
• Inventors: Kruckenberg, Teresa M., Hill, Valerie A., Young, Eloise, Chiou, Song, Mazany, Anthony Michael
• Primary Examiner(s): COLE, ELIZABETH M
• Application Number:
  US12/282,305
• Publication Number:
  US 20090227162A1
• Time in Patent Office: 2,909 Days
• Field of Search: 442/6, 442/204, 977/778, 977/785, 977/961, 428/367, 428/297.4, 922/920, 922/773, 922/775
• US Class Current: 428/297.4
• CPC Class Codes: B64D 45/02 Lightning protectors; Static dischargers in general H01T
• CPC Class Codes: C09D 5/24 Electrically-conducting paints conductive materials H01B1/00
• CPC Class Codes: Y10S 977/773 Nanoparticle, i.e. structure having three dimensions of 100 nm or less
• CPC Class Codes: Y10S 977/775 Nanosized powder or flake, e.g. nanosized catalyst
• CPC Class Codes: Y10S 977/778 within specified host or matrix material, e.g. nanocomposite films
• CPC Class Codes: Y10S 977/785 Electrically insulating host material
• CPC Class Codes: Y10S 977/92 Detection of biochemical
• CPC Class Codes: Y10S 977/961 for textile or fabric treatment
• CPC Class Codes: Y10T 428/24994 Fiber embedded in or on the surface of a polymeric matrix
• CPC Class Codes: Y10T 428/268 Monolayer with structurally defined element
• CPC Class Codes: Y10T 428/2918 including free carbon or carbide or therewith [not as steel]
• CPC Class Codes: Y10T 442/10 Scrim [e.g., open net or mesh, gauze, loose or open weave or knit, etc.]
• CPC Class Codes: Y10T 442/2475 Coating or impregnation is electrical insulation-providing, -improving, or -increasing, or conductivity-reducing
• CPC Class Codes: Y10T 442/3187 Triaxially woven fabric

Abstract

Surface films, paints, or primers can be used in preparing aircraft structural composites that may be exposed to lightning strikes. Methods for making and using these films, paints or primers are also disclosed. The surface film can include a thermoset resin or polymer, e.g., an epoxy resin and/or a thermoplastic polymer, which can be cured, bonded, or painted on the composite structure. Low-density electrically conductive materials are disclosed, such as carbon nanofiber, copper powder, metal coated microspheres, metal-coated carbon nanotubes, single wall carbon nanotubes, graphite nanoplatelets and the like, that can be uniformly dispersed throughout or on the film. Low density conductive materials can include metal screens, optionally in combination with carbon nanofibers.

Claims

1. A film for providing a desired level of lightning strike protection to a composite or metal substrate, the film comprising carbon nanoparticle yarn infiltrated with resin, wherein the carbon nanoparticles comprise carbon nanotubes, the carbon nanotubes are aligned through mechanical or chemical methods, the yarn is in the form of a braid disposed on the surface of the substrate, the maximum gap between adjacent yarns is less than about 0.120 inches (3.05 mm), and the yarn is present at a loading level that provides Zone 1A lightning strike protection.

2. The film of claim 1, wherein the carbon nanoparticle yarn further comprises graphite nanoplatelets.

3. The film of claim 2, wherein the graphite nanoplatelets are structurally aligned through vibration, shear flow, or covalent bonding.

4. The film of claim 1, wherein the carbon nanotubes are aligned through optimizing the nanotubes to react with the tail or head of each nanotube such that it will self-assemble into alignment.

5. The film of claim 1, wherein the carbon nanotubes are aligned through vibration extrusion techniques.