Hughes Aircraft Company

Hughes Electronics Corporation

Other

The Boeing Company

John P Stafford

Preston S DuPont

Robert E Ritter

Nancy J Condon

Walter Rex Oswald

Susan K Ferer

Steven J Stadnick

Robert K Taenaka

Edward K Hoffman

Gary L Duncan

Roderick A Bulante

Florian J Zukas

Michael Langmack

Patrick B Cooke

Matt H Russell

Dennis Quan

Sung H Lee

Troy A Conwell

A fuse/support assembly for attachment to an electrical bus includes a base plate having a substrate made of an insulator, a fastener bore extending through the substrate, and an electrically conductive path on the substrate. There is additionally an external connector structure. A fuse is supported on the substrate and has a first end in electrical communication with the external connector and a second end in electrical communication with the electrically conductive path.

Electrical fuse/support assembly

A heat sink board structure includes a thermal/structural base having a composite core layer of a mass of graphitized carbon fibers infiltrated with a first resin material matrix. The graphitized carbon fibers of the composite core are substantially unidirectional and oriented parallel to the face of the composite core layer. Transverse reinforcement layers are bonded to the oppositely disposed faces of the composite core layer. Each transverse reinforcement layer is formed of carbon fibers embedded in a resin material matrix, with the carbon fibers lying substantially in a plane of the transverse reinforcement layer and perpendicular to the carbon fibers in the composite layer. Heat generating and heat dissipating components are bonded to the thermal/structural base. Metallic contact strips are bonded to the surfaces of the transverse reinforcement layers.

Composite heat sink/support structure

A face sheet is bonded to a porous core by contacting adhesive to the porous core at the bonding face, placing a screen stripping sheet overlying the adhesive, and pressing on the stripping sheet while heating the core and adhesive. The adhesive is thereby forced against the exposed portions of the cell walls at the bonding face and into the interstices of the stripping sheet. The excess adhesive not contacting the exposed cell walls is removed by cooling the stripping sheet and adhesive, and peeling the stripping sheet and excess adhesive from the core. A face sheet is bonded to the porous core with the remaining adhesive that adhered to the exposed cell walls.

Preparation of adhesively bonded sandwich structures

A battery system includes a battery cell having a cylindrical battery cell housing and a housing support external to the battery cell housing. The housing support is formed of an electrical insulator layer contacting the cylindrical external surface of the battery cell housing, and a heat conductor formed of heat-conducting fibers overlying and contacting the electrical insulator layer and aligned generally parallel to the cylindrical axis of the battery cell housing. The heat-conducting fibers are made of high-thermal-conductivity graphite and have a sink end. A fiber-reinforced composite structural support layer is applied overlying the heat-conducting fibers to force the electrical insulator layer into contact with the battery cell housing without the presence of an adhesive between the electrical insulator and the battery cell housing. A thermal sink is in thermal contact with the sink ends of the plurality of heat-conducting fibers at a first end of the cylindrical battery cell housing. A structural base joined to the structural support layer is positioned at a second end of the cylindrical battery cell housing.

Battery system with a high-thermal-conductivity integral structural

A battery system includes a battery cell having a battery cell housing, and a housing support external to the battery cell housing. The housing support is formed of at least two split shell segments. Each split shell segment includes a heat conductor inner layer having a plurality of heat-conducting fibers with heat sink ends, and a structural support outer layer overlying the heat conductor inner layer. The structural support layer is made of a fiber-reinforced composite material. A layer of a structural adhesive bonds the respective heat conductor inner layer of each split shell segment to the battery cell housing. A thermal sink is in thermal contact with the sink ends of the plurality of heat-conducting fibers of each of the split shell segments, and the structural support outer layer of each split shell segment is joined to a structural base. Preferably, a number of the battery cells and overlying housing supports extend between a single thermal sink at one end and a single structure base at the other end, forming a battery pack.

Battery system with a high-thermal-conductivity split shell structural

Conductive coating (20) is a thorough mixture of 0.03 parts per weight of carbon black together with 0.003 to 0.01 parts per weight of wetting agent and 20 parts of solvent, and further mixing in by low shearing mixing 1/2 to 1 part per weight of thermosetting resin. This is then sprayed into place on the substrate and thermoset. In this particular case, the substrate is exterior face sheet (12) of honeycomb structure (10) which may serve as part of a spacecraft, to electrically conduct away surface charges.

Conductive coating

Electrically conductive composite structure

Conductive coating (20) is produced by the process of first mixing by high shear mixing a mixture of 0.03 parts per weight of carbon black together with 0.003 to 0.01 parts per weight of wetting agent and 20 parts of solvent, and further mixing in by low shear mixing 1/2 to 1 part per weight of thermosetting resin. Prior to application this is then sprayed into place on the substrate. In this particular case, the substrate is exterior face sheet (12) of honeycomb structure (10) which may serve as part of a spacecraft, to electrically conduct away surface charges.

Conductive coating process

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Yorba Linda, CA, United States of America

John P Stafford