ELECTRICALLY CONDUCTIVE STRUCTURE

• US 20130005208A1
• Filed: 06/30/2011
• Published: 01/03/2013
• Est. Priority Date: 06/30/2011
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Retz, Kevin Matthew, Prichard, Alan Keith
• Granted Patent: US 9,108,387 B2
• Time in Patent Office: Days
• US Class Current: 442/189
• CPC Class Codes: B32B 2262/106 Carbon fibres, e.g. graphite fibres
• CPC Class Codes: B32B 2307/202 Conductive
• CPC Class Codes: B32B 5/024 Woven fabric
• CPC Class Codes: B32B 5/22 characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed layer formed of natural mineral fibres or particles next to a foam layer B32B19/047, next to a layer made of particles B32B19/048, or next to a fibrous or filamentary layer B32B19/06; paper layer or cardboard layer next to a paper layer or cardboard layer B32B29/005, next to a foam layer B32B29/007, next to a fibrous or filamentary layer B32B29/02, or next to a particulate layer B32B29/04
• CPC Class Codes: B64D 45/02 Lightning protectors; Static dischargers in general H01T
• CPC Class Codes: D03D 1/0088 Fabrics having an electronic function
• CPC Class Codes: D03D 13/004 with weave pattern being non-standard or providing special effects
• CPC Class Codes: D03D 15/258 Noble metal
• CPC Class Codes: H10K 85/221 Carbon nanotubes
• CPC Class Codes: Y10T 442/3065 Including strand which is of specific structural definition
• CPC Class Codes: Y10T 442/3195 Three-dimensional weave [e.g., x-y-z planes, multi-planar warps and/or wefts, etc.]

Abstract

An electrically conductive structure includes a plurality of carbon fiber layers and at least one electrically conductive filament three-dimensionally woven among the carbon fiber layers. The plurality of carbon fiber layers and the at least one electrically conductive filament are operable to conduct electrical current throughout the structure.

Claims

1. An electrically conductive structure with improved conductivity and electromagnetic dissipation, comprising:

a plurality of carbon fiber layers; and

at least one electrically conductive filament three-dimensionally woven among said carbon fiber layers, wherein said plurality of carbon fiber layers and said at least one electrically conductive filament are operable to conduct electrical current throughout said structure.

2. The electrically conductive structure of claim 1 wherein said at least one electrically conductive filament comprises a plurality of electrically conductive filaments.

3. The electrically conductive structure of claim 2 wherein said electrically conductive filaments are discontinuous and electrical current transfers between said conductive filaments via electron tunneling.

4. The electrically conductive structure of claim 2 wherein said electrically conductive filaments are discontinuous and electrical current transfers between said conductive filaments via capacitive coupling.

5. The electrically conductive structure of claim 1 wherein said at least one electrically conductive filament comprises a woven, braided or spun fine metallic wire.

6. The electrically conductive structure of claim 1 wherein said at least one electrically conductive filament comprises a dry conductive graphite fiber.

7. The electrically conductive structure of claim 1 wherein said at least one electrically conductive filament comprises a carbon nano-filament.

8. The electrically conductive structure of claim 1 wherein said plurality of carbon fiber layers are pre-impregnated with resin.

9. An electrically conductive structure with improved conductivity and electromagnetic dissipation, comprising:

at least a first carbon fiber layer having a plurality of carbon fiber tows oriented along an X axis and a second carbon fiber layer having a second plurality of carbon fiber tows adjacent to said first carbon fiber layer and oriented along a Y axis;

a plurality of electrically conductive filaments woven among said carbon fiber layers along a Z axis;

said carbon fiber tows and said electrically conductive filaments are operable to conduct electrical current throughout said structure.

10. The electrically conductive structure of claim 9 wherein said at least one electrically conductive filament comprises a plurality of electrically conductive filaments.

11. The electrically conductive structure of claim 10 wherein said electrically conductive filaments are discontinuous and electrical current transfers between said conductive filaments via electron tunneling.

12. The electrically conductive structure of claim 10 wherein said electrically conductive filaments are discontinuous and electrical current transfers between said conductive filaments via capacitive coupling, and HF Inductive coupling.

13. The electrically conductive structure of claim 9 wherein said at least one electrically conductive filament comprises a woven fine metallic wire.

14. The electrically conductive structure of claim 9 wherein said at least one electrically conductive filament comprises a dry conductive graphite fiber.

15. The electrically conductive structure of claim 9 wherein said at least one electrically conductive filament comprises a carbon nano-filament.

16. The electrically conductive structure of claim 9 wherein said plurality of carbon fiber layers are pre-impregnated with resin.

17. A method of dissipating an electrical current in a composite structure, comprising:

providing carbon fiber tow layers along X and Y axes;

weaving at least one electrically conductive filament among said carbon fiber tow layers and extending along an X axis;

pre-impregnating said carbon fiber tow layers with resin;

completing said composite structure by curing said resin;

and dissipating electrical current throughout said composite structure along said carbon fiber tow layers and said at least one electrically conductive filament.

18. The method of claim 17 wherein said weaving at least one electrically conductive filament among said carbon fiber tow layers and extending along an X axis comprises weaving a plurality of electrically conductive filaments among said carbon fiber tow layers and extending along an X axis.

19. The method of claim 17 further comprising incorporating said composite structure into a higher-order structure.

20. The method of claim 19 wherein said incorporating said composite structure into a higher-order structure comprises incorporating said composite structure into an aircraft.