Electrically conductive and insulative composite

Abstract

An electrically conductive and insulative composite (ECIC) is disclosed. In various embodiments, an ECIC as disclosed herein may include an electrically conductive structural element and one or more electrically insulative structural elements adhesively bonded to the conductive structural element to form a unitized structure having a design shape and one or more significant mechanical properties. The conductive structural element is substantially encapsulated by said one or more electrically insulative structural elements with the exception of one or more contact areas comprising portions of conductive material not encapsulated by said one or more electrically insulative structural elements.

What is claimed is: 
     
         1 . An electrically conductive and insulative composite spar structure, comprising:
 an electrically conductive structural element; and   one or more electrically insulative structural elements comprising an electrically insulative composite material adhesively bonded to the conductive structural element to form a rigid unitized structure having a design shape and one or more significant mechanical properties, including rigidity and strength;   wherein the conductive structural element is substantially encapsulated by said one or more electrically insulative structural elements with the exception of one or more contact areas comprising portions of conductive material not encapsulated by said one or more electrically insulative structural elements.   
     
     
         2 . The spar structure of  claim 1 , further comprising a web section joined to a first cap section, wherein at least a portion of the web section is substantially perpendicular to the first cap section. 
     
     
         3 . The spar structure of  claim 2 , further comprising a second cap section substantially parallel to the first cap section and joined to the first cap section by the web section. 
     
     
         4 . The spar structure of  claim 1 , wherein said conductive structural element comprises a conductive bar or bus having an associated mechanical strength and rigidity. 
     
     
         5 . The spar structure of  claim 4 , wherein said conductive structural element comprises an electrically conductive metal. 
     
     
         6 . The spar structure of  claim 1 , wherein said electrically insulative composite material comprises one or more of fiber-reinforced polymer material, fiberglass, or innegra. 
     
     
         7 . The spar structure of  claim 1 , wherein said electrically insulative composite material has one or more mechanical properties that contribute to satisfying a design requirement of a system in which the electrically conductive and insulative composite structure is designed to be integrated. 
     
     
         8 . The spar structure of  claim 1 , further comprising one or more additional structural elements bonded to said one or more electrically insulative structural elements. 
     
     
         9 . The spar structure of  claim 8 , wherein one or more of said additional structural elements comprises at least one of a composite layer and an electromagnetic shielding element. 
     
     
         10 . The spar structure of  claim 8 , wherein said electrically conductive structural element, said one or more electrically insulative structural elements, and said one or more additional structural elements comprise a single unitized structure having a design shape and one or more significant mechanical properties. 
     
     
         11 . The spar structure of  claim 1 , wherein one or more of said electrically conductive structural elements each includes at least two contact areas separated by a distance enabling a flow of electrical current between said contact areas. 
     
     
         12 . The spar structure of  claim 1 , wherein said contact areas comprise portions of conductive material that are exposed by removing or omitting encapsulating material. 
     
     
         13 . The spar structure of  claim 1 , wherein said contact areas comprise portions of conductive material that extend away from a main body portion of said electrically conductive structural element. 
     
     
         14 . The spar structure of  claim 1 , wherein said electrically conductive structural element comprises a first electrically conductive structural element and further comprising a second electrically conductive structural element, electrically isolated from said first electrically conductive structural element, each of the first and second electrically conductive structural elements having a pair of contact areas, one at each of two locations separated by a distance, enabling an electrical circuit to be made of which the first electrically conductive structural element and the second electrically conductive structural element comprise low impedance segments. 
     
     
         15 . A method to manufacture an electrically conductive and insulative composite spar structure, comprising:
 forming an electrically conductive structural element; and   bonding one or more electrically insulative structural elements adhesively to the conductive structural element to form a rigid unitized structure having a design shape and one or more significant mechanical properties including rigidity and strength, wherein the conductive structural element is substantially encapsulated by said one or more electrically insulative structural elements with the exception of one or more contact areas comprising portions of conductive material not encapsulated by said one or more electrically insulative structural elements.   
     
     
         16 . The method of  claim 15 , further comprising joining a web section to a first cap section, wherein at least a portion of the web section is substantially perpendicular to the first cap section. 
     
     
         17 . The method of  claim 15 , further comprising joining a second cap section to the web section wherein the second cap section is substantially parallel to the first cap section. 
     
     
         18 . The method of  claim 15 , further comprising bonding one or more additional structural elements to said one or more electrically insulative structural elements. 
     
     
         19 . The method of  claim 18 , further comprising forming in each of one or more of said electrically conductive structural elements at least two contact areas separated by a distance enabling a flow of electrical current between said contact areas. 
     
     
         20 . An airfoil, comprising:
 a spar structure including:
 an electrically conductive structural element; and 
 one or more electrically insulative structural elements comprising an electrically insulative composite material adhesively bonded to the conductive structural element to form a rigid unitized structure having a design shape and one or more significant mechanical properties, including rigidity and strength; 
 wherein the conductive structural element is substantially encapsulated by said one or more electrically insulative structural elements with the exception of one or more contact areas comprising portions of conductive material not encapsulated by said one or more electrically insulative structural elements.