The supersession of metallic alloys with lightweight, high-strength composites is
popular in the aircraft industry. However, aviation electronic enclosures for
large format batteries and high power conversion electronics are still primarily
made of aluminum alloys. These aluminum enclosures have attractive properties
regrading structural integrity for the heavy internal parts, electromagnetic
interference (EMI) suppression, electrical bonding for the internal cells,
and/or electronics and failure containment.
This paper details a lightweight carbon fiber composite chassis developed at
Meggitt Sensing Systems (MSS) Securaplane, with a copper metallic mesh co-cured
onto the internal surfaces resulting in a 50% reduction in weight when compared
to its aluminum counterpart. In addition to significant weight reduction, it
provides equal or improved performance with respect to EMI, structural and
flammability performance. This application of the technology outlined in this
paper pertains to an engine-start battery chassis. However, strategically
embedding metallic mesh within composite materials may be utilized in numerous
other applications of aviation electronics enclosures.
