Different strategies have been implemented in a multipanel prototype. The approach developed by TECNALIA in DEFLECT project has been focused on the embedment of a network of electrical wires and fibre optics inside the composite. In this way, the typical cumbersome harness usually found in an electrical cabinet is avoided (instead, wires are placed inside the panel). In addition, mechanical inserts and electrical connectors have been also embedded in the laminate during the manufacturing process. All the functional elements (electric wires, fibre optics, inserts and connectors) are placed in dedicated areas of the mould where the composite laminate is produced. The approach followed by IRT Saint Exupery was focused instead on the embedment of aluminum bus bars directly in the core of the panel. This strategy allows further reducing the space and volume of the cabinet required for a specific electric design.
In the first stage of the project, embedment / encapsulation trials and simple testing for evaluation of all the preselected materials (REACH Compliant) and configurations were carried out. With the selected materials, detailed material characterization and validation was performed. The material has been subjected to an exhaustive validation campaign according to RTCA-DO-160 standard. All the tests have been successfully accomplished. Indicated requirements have been fulfilled. It is noteworthy the fire performance of the system: flammability, smoke and toxicity and optical density and the ISO 2685 standard (15 minutes) tests have been passed. Once the materials have been validated, the detailed design and manufacturing of each of the panels that form the Electrical Cabinet has been carried out.
As a result, versatile strategies to integrate elements such as bus bars, wires, optical fibres, connectors, inserts, etc, have been successfully developed. Multifunctional structural panels have been obtained. Solutions developed are enabling technologies for multiple applications.
If only the weight of the panel is considered, solutions are not lighter than the current Nomex panel used for the manufacturing of light cabinets. But the new material is more resistant, more damage tolerant and features a very high embedding ability. Considering the mass of additional elements required in the traditional solution such as attachments, screws, etc (the whole system), the approaches developed in DEFLECT are very competitive. A smaller cabinet could be manufactured and a mass saving of around 5 to 10 % has been estimated.
Considering that many components are directly placed during the manufacturing of the laminate, this will also facilitate assembly operations reducing cost and the probability e.g. of improper connection of the hardware.
Notes about the project have been included in the webpage of the Consortium and in “Estrategia” Magazine. In addition, outputs of the project were presented in the ICCST12 conference. A representative panel was going to be presented in the JEC World Paris 2020. However, this event has been cancelled due to COVID 19.
Currently, the possibility to patent the outcomes of DEFLECT project is being analyzed. Broad dissemination of results (paper, conference, etc) has been postponed up to having the result of the patent studies.
The results of this project have allowed IRT-SE improving its understanding of the physical phenomena behind the consolidation and the thermal stability of thermoset composites and to acquire a critical know-how in this field. These results will be then used to propose new project with the IRT Industrial and SME partners..
Knowledge gained in the project will strengthen TECNALIA’s position as a niche technology provider of advanced composite components. Lightweight composite housings are a major technology focus on TECNALIA. However, several other applications have already been identified where this new multifunctional material could play an important role for reducing mass and overall manufacturing cost..
