Mcdonnell Douglas Corporation

Bruce E McIlroy

Jack Howard Jacobs

Matthew M Thomas

Robert A Glowasky

A connector tow for providing external electrical access to an electrical device embedded within a composite structure. The connector comprises a plurality of tubes disposed between a pair of opposed film layers. The film layers are adhered to opposite sides of the plurality of tubes and can be comprised of an insulating material so as to electrically isolate the plurality of tubes. By extending through the edge surface of the composite structure, the electrical ports can be accessed during the fabrication of the a composite structure such that the operations of the embedded electrical device can be monitored.

Connector tow

A method is provided for fabricating a composite structure having an externally accessible electrical device embedded therein. At least one supporting ply is initially provided that has first and second depressions. An electrical device having at least one electrical lead is disposed in the first depression and a connector tow having at least one tube with opposed first and second ends is disposed in the second depression. The first end of the tube of the connector tow is electrically connected to the electrical lead. Thereafter, at least one additional ply is stacked on the supporting ply such that the electrical device and the connector tow are embedded. The stacked plies can then be consolidated to form an integral laminate structure. Following the consolidation, the second end of the tube of the connector tow can be accessed through the edge surface of the laminate structure to thereby define an externally accessible electrical port for receiving a corresponding connector. As such, electrical contact can be established with the embedded electrical device via the tube and the electrical lead. By establishing electrical contact with the electrical device during the fabrication process, the operation and therefore the health of the embedded electrical device can thereafter be monitored.

Composite structure having an externally accessible electrical device

A composite structure having an externally accessible electrical device embedded therein includes at least one tube disposed within the composite structure and extending from a first end which is electrically connected to an electrical lead of the electrical device to a second end which opens through the edge surface of the composite structure to thereby define an externally accessible electrical port. By plugging a corresponding connector into the electrical port, electrical contact can be established via the electrical lead with the electrical device embedded within the composite structure. By extending through the edge surface of the composite structure, the electrical ports can be accessed during the fabrication of the composite structure such that the operations of the embedded electrical device can be monitored. In addition, the edge surface of the resulting composite structure can be machined or cut so as to render the respective second ends of any embedded tubes flush with the machined edge of the composite structure to more precisely define the respective electrical ports.

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Florissant, MO, United States of America

Bruce E McIlroy