Nautilus Defense LLC

Zane A Lewis

James B Owens, Jr

Patrick M Wynn

Braided composite yarns including one or more functional components such as conductors and one or more structural components such as para-aramid fibers, and methods of manufacture therefor. Bundles of at least one functional component and at least one structural component undergo simultaneous parallel winding under tension onto a single bobbin prior to braiding, thus reducing the mechanical loading forces on the functional components in the final yarn. The yarns can be engineered with application-specific electrical, electronic, electromagnetic, or physical properties that enable their use as electronic components or sensors, and attached to or incorporated into active textiles and composite substrates. Such yarns can be used to measure elongation, compression, twist, and other properties of a braided object in which they are incorporated.

Functional braided composite yarns for sensing applications

Braided composite yarns including one or more functional components such as conductors and one or more structural components such as para-aramid fibers, and methods of manufacture therefor. Bundles of at least one functional component and at least one structural component undergo simultaneous parallel winding under tension onto a single bobbin prior to braiding, thus reducing the mechanical loading forces on the functional components in the final yarn. The yarns can be engineered with application-specific electrical, electronic, electromagnetic, or physical properties that enable their use as electronic components or sensors, and attached to or incorporated into active textiles and composite substrates. The yarns can be directly soldered to without prior removal of insulation or other yarn components. Some yarns, such as those for use as inductors, can include a core with desired electrical properties.

Functional braided composite yarn

A composite material comprising braided composite yarns that can be embedded within or at the surface of the material. The braided composite yarns can incorporate one or more multicomponent fiber bundles. The braided composite yarns can be the axial yarns in a triaxial braided fabric that has structural yarns as the bias yarns. The composite material can comprise a carbon fiber prepreg. The thickness of each braided composite yarn can be approximately the thickness of a single composite ply. At least one conductive wire can be wrapped around an axial yarn of the braided composite yarn at a location desirable for electrical contact to be made to at least one conductor in the axial yarn. At least some of the conductive wire is preferably soldered to at least one of the conductors. The conductive wire can be twisted with a structural yarn and is stitched across the braided composite yarn. A conductive pad can be soldered to the one conductive wire.

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Foster, RI, United States of America

Zane A Lewis