U.S. patent application number 14/570827 was filed with the patent office on 2016-06-16 for super light weight electronic circuit and low power distribution in aircraft systems.
The applicant listed for this patent is The Boeing Company. Invention is credited to Morteza Safai.
Application Number | 20160174369 14/570827 |
Document ID | / |
Family ID | 56112553 |
Filed Date | 2016-06-16 |
United States Patent
Application |
20160174369 |
Kind Code |
A1 |
Safai; Morteza |
June 16, 2016 |
SUPER LIGHT WEIGHT ELECTRONIC CIRCUIT AND LOW POWER DISTRIBUTION IN
AIRCRAFT SYSTEMS
Abstract
A method and system for applying conductive traces to a
structure to complete an electrical circuit. One or more graphene
traces is formed on a substrate. The substrate is applied to the
structure such that one or more first portions of the electrical
circuit are electrically connected to respective one or more second
portions of the electrical circuit by respective ones of the one or
more graphene traces. The substrate may be removed from the
structure such that the graphene traces remain on the structure.
The structure is preferably a fuselage of an aircraft and is formed
from a composite material. The substrate may be applied to the
structure is prior to curing of the composite material and/or prior
to a complete formation of the fuselage, such that, after the
fuselage is completely formed, the one or more graphene traces
become embedded within the composite material forming the
fuselage.
Inventors: |
Safai; Morteza; (Newcastle,
WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Boeing Company |
Chicago |
IL |
US |
|
|
Family ID: |
56112553 |
Appl. No.: |
14/570827 |
Filed: |
December 15, 2014 |
Current U.S.
Class: |
362/382 ; 29/831;
361/748 |
Current CPC
Class: |
B64C 1/061 20130101;
B64D 2221/00 20130101; H05K 2203/0191 20130101; H05K 1/097
20130101; H05K 3/207 20130101; H05K 2201/0323 20130101 |
International
Class: |
H05K 1/02 20060101
H05K001/02; F21K 99/00 20060101 F21K099/00; H05K 3/20 20060101
H05K003/20 |
Claims
1. A method for applying conductive traces to a structure to
complete an electrical circuit, comprising the steps of: forming
one or more graphene traces on a substrate; and applying the
substrate to the structure such that one or more first portions of
the electrical circuit are electrically connected to respective one
or more second portions of the electrical circuit by respective
ones of the one or more graphene traces.
2. The method of claim 1, further comprising the step of removing
the substrate from the structure such that the graphene traces
remain on the structure.
3. The method of claim 1, wherein the structure comprises a
fuselage of an aircraft.
4. The method of claim 3, wherein the fuselage of the aircraft is
formed from a composite material, and the step of applying the
substrate to the structure is performed prior to curing of the
composite material.
5. The method of claim 3, wherein the fuselage of the aircraft is
formed from a composite material, and wherein the step of applying
the substrate to the structure is performed prior to a complete
formation of the fuselage, such that, after the fuselage is
completely formed, the one or more graphene traces become embedded
within the composite material forming the fuselage.
6. The method of claim 1, further comprising the step of using at
least one of the one or more graphene traces to conduct electrical
signals.
7. The method of claim 1, further comprising the step of using at
least one of the one or more graphene traces to conduct electrical
power.
8. The method of claim 1, wherein the applying substrate to the
structure bonds the substrate to the structure so that the
substrate acts as an insulator for the one or more graphene
traces.
9. The method of claim 1, wherein the substrate includes additional
electrical circuitry.
10. The method of claim 9, wherein the additional electrical
circuitry comprises one or more organic light emitting diodes.
11. A method for applying conductive traces to a structure to
complete an electrical circuit, comprising the steps of: forming
one or more graphene traces on a substrate; applying the substrate
to the structure such that one or more first portions of the
electrical circuit are electrically connected to respective one or
more second portions of the electrical circuit by respective ones
of the one or more graphene traces; and removing the substrate from
the structure such that the graphene traces remain on the
structure.
12. The method of claim 11, wherein the structure comprises a
fuselage of an aircraft.
13. The method of claim 12, wherein the fuselage of the aircraft is
formed from a composite material, and the step of applying the
substrate to the structure is performed prior to curing of the
composite material.
14. The method of claim 12, wherein the fuselage of the aircraft is
formed from a composite material, and wherein the step of applying
the substrate to the structure is performed prior to a complete
formation of the fuselage, such that, after the fuselage is
completely formed, the one or more graphene traces become embedded
within the composite material forming the fuselage.
15. The method of claim 11, further comprising the step of using at
least one of the one or more graphene traces to conduct electrical
signals.
16. The method of claim 11, further comprising the step of using at
least one of the one or more graphene traces to conduct electrical
power.
17. A system for electrically coupling two portions of one or more
electrical circuits, comprising: a substrate; and one or more
graphene traces formed on the substrate, each of the one or more
graphene traces adapted to electrically couple a first portion of a
respective one of the one or more electrical circuits to a second
portion of the respective one of the one or more electrical
circuits.
18. The system of claim 17, further comprising additional
electrical circuitry formed on the substrate.
19. The system of claim 18, wherein the additional electrical
circuitry comprises one or more organic light emitting diodes.
20. The system of claim 17, wherein at least one portion of the one
or more electrical circuits is mounted on an interior surface of an
aircraft fuselage.
Description
FIELD
[0001] This disclosure relates generally to electrical conductors,
and more specifically, to highly conductive electrical circuits
that are reduced in weight as compared to copper and aluminum wire
conductor implementations that are equivalent in conductivity.
BACKGROUND
[0002] It is a continuing goal to reduce the cost and weight of
aircraft, spacecraft, and many other devices that include one or
more electrical functions. Aircraft, for example, typically include
thousands of feet of copper or aluminum wire embedded in an
insulator. This wire requires a great deal of time for both
manufacturing and installation, and contributes a great deal to the
weight of the aircraft. Added weight results in a corresponding
increase in fuel consumption and/or a decrease in payload
capacity.
[0003] In most existing applications, electrical power, current,
and electrical signals are typically conducted through wires or
cables using copper or aluminum as the conductive medium. In these
applications, the amount of power, current, and signal strength are
inherently limited by the electrical resistivity of the conducting
materials, such as copper and aluminum, used to implement the
electrical path. In addition, since copper and aluminum conductors
include a resistance, current flowing through such conductors
causes the wire to generate heat. A conductor with a lower
resistance per unit area will tend to reduce the amount of heat
generated (and electrical energy lost due to such generated heat)
within a system.
[0004] Accordingly, there is a need for an electrical conductor for
use in aircraft which overcomes the drawbacks of conventional
copper and aluminum conductors.
SUMMARY
[0005] In one aspect, a method for applying conductive traces to a
structure to complete an electrical circuit. One or more graphene
traces are formed on a substrate. Then the substrate is applied to
the structure such that one or more first portions of the
electrical circuit are electrically connected to respective one or
more second portions of the electrical circuit by respective ones
of the one or more graphene traces.
[0006] In a further embodiment, the substrate may be removed from
the structure such that the graphene traces remain on the
structure. In addition, the structure may comprise a fuselage of an
aircraft. Further, the fuselage of the aircraft may be formed from
a composite material, and the substrate may be applied to the
structure prior to curing of the composite material. Alternatively,
when the fuselage of the aircraft is formed from a composite
material, the substrate may be applied to the structure prior to a
complete formation of the fuselage, such that, after the fuselage
is completely formed, the one or more graphene traces become
embedded within the composite material forming the fuselage. The at
least one of the one or more graphene traces may be used to conduct
electrical signals and/or electrical power. The substrate may be
bonded to the structure when applied so that the substrate acts as
an insulator for the one or more graphene traces. Still further,
the substrate may include additional electrical circuitry. The
additional electrical circuitry may be one or more organic light
emitting diodes.
[0007] In another aspect, a method for applying conductive traces
to a structure to complete an electrical circuit. One or more
graphene traces is formed on a substrate. The substrate is applied
to the structure such that one or more first portions of the
electrical circuit are electrically connected to respective one or
more second portions of the electrical circuit by respective ones
of the one or more graphene traces. Finally, the substrate is
removed from the structure such that the graphene traces remain on
the structure.
[0008] In a still further aspect, a system for electrically
coupling two portions of one or more electrical circuits. The
system includes a substrate and one or more graphene traces formed
on the substrate. Each of the one or more graphene traces is
adapted to electrically couple a first portion of a respective one
of the one or more electrical circuits to a second portion of the
respective one of the one or more electrical circuits. The system
may further include additional electrical circuitry formed on the
substrate. The additional electrical circuitry may be one or more
organic light emitting diodes. Finally, at least one portion of the
one or more electrical circuits may be mounted on an interior
surface of an aircraft fuselage.
[0009] The features, functions, and advantages that have been
discussed can be achieved independently in various embodiments or
may be combined in yet other embodiments, further details of which
can be seen with reference to the following description and
drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The following detailed description, given by way of example
and not intended to limit the present disclosure solely thereto,
will best be understood in conjunction with the accompanying
drawings in which:
[0011] FIG. 1 is a diagram showing graphene traces on an interior
surface of an aircraft fuselage according to an embodiment of the
present disclosure; and
[0012] FIG. 2 is a diagram showing graphene traces pre-printed on a
substrate roll according to an aspect of the present
disclosure.
DETAILED DESCRIPTION
[0013] In the present disclosure, like reference numbers refer to
like elements throughout the drawings, which illustrate various
exemplary embodiments of the present disclosure.
[0014] Graphene is a one-atom-thick planar sheet of sp.sup.2-bonded
carbon atoms that are densely packed in a honeycomb (hexagonal)
crystal lattice. Graphene has a density of approximately 1.7
g/cm.sup.3. Graphene is strong, light, nearly transparent and an
excellent conductor of heat and electricity. The carbon/carbon bond
length in graphene can be as thick as 0.142 nanometers. Graphene
nanosheets are formed from layers of graphene. Graphene has a high
carrier mobility and low noise susceptibility and thus is quite
useful in electronic circuits.
[0015] Referring now to FIG. 1, according to the present
disclosure, conductive traces 110 formed from graphene nanosheets
are bonded to the inner surface of a fuselage 100 of an aircraft to
complete a number of electrical circuits. Such conductive traces
110 may provide low-voltage power to interior cabin lighting 120
and to window heaters 130 from a power source. In addition, the
conductive traces 110 may also pass electrical signals to other
electrical equipment within the aircraft, for example, digital
audio and/or video signals for entertainment systems, electrical
power for emergency lighting systems, etc. from a main distribution
point. As one of ordinary skill in the art will readily recognize,
the conductive traces 110 formed from graphene nanosheets may
replace any of the conventional wiring in an aircraft used for such
purposes.
[0016] Referring now to FIG. 2, the graphene traces 210 may be
formed on an appropriate substrate 200 as a single roll 220 of
graphene decals, with all circuit traces pre-printed on the
substrate 200 of such rolls. Substrate 200 may be formed from, for
example, carbon fiber tape, fiberglass tape or Kevlar tape. These
rolls 220 can bonded to structures (such as the fuselage 100 in
FIG. 1). In one embodiment, the substrate 200 may be removed,
leaving the graphene traces 210 behind on the surface of such
structure. Notably, because graphene can stand high temperature,
the graphene traces 210 can withstand high temperature curing of a
composite in an auto clave, making this circuitry desirable for use
with fuselages formed from composite materials. In another
embodiment, the original substrate 200 can also be bonded to the
structure and serve as a protective layer for the graphene traces
210 (e.g., for insulation purposes). In a still further embodiment,
the rolls 220 may be bonded to a fuselage formed from a composite
during manufacturing of such fuselage such that, after substrate
200 is removed, formation of the fuselage continues and the
graphene traces 210 become embedded within the composite
material.
[0017] In FIG. 2, the graphene traces 210 are pre-printed on a bare
substrate 200 that is formed into a roll 220. In the alternative,
the graphene traces 210 may be preprinted on substrates which also
include other types of circuits, e.g., OLEDs (organic light
emitting diodes), P-OLEDs (polymer organic light emitting diodes),
etc., such that the substrate, when mounted on the inner surface of
the fuselage, can provide additional functionality, e.g., interior
lighting, based on the included additional circuits.
[0018] The use of graphene traces, as opposed to conventional
copper or aluminum wiring, can provide significant savings in both
weight and manufacturing costs. These circuits based on graphene
traces can be embedded in an aircraft fuselage formed from either a
composite material or a metal material, and in other structures
formed from composites and/or metal. The elimination of
conventional copper or aluminum wiring provides a significant
weight savings and a significant reduction in the manufacturing and
assembly process of the aircraft. This results in both a
significant reduction in cost of each aircraft and an improved per
mile revenue for each aircraft because of fuel savings achieved by
the lighter aircraft.
[0019] Although the present disclosure has been particularly shown
and described with reference to the disclosed embodiments and
various aspects thereof, it will be appreciated by those of
ordinary skill in the art that various changes and modifications
may be made without departing from the spirit and scope of the
disclosure. It is intended that the appended claims be interpreted
as including the embodiments described herein, the alternatives
mentioned above, and all equivalents thereto.
* * * * *