Non-Parasitic, High Strength-to-Weight Ratio, EM Immune, Flexible Aramid Composite Conduit

ABSTRACT: NanoSonic has recently developed high-strength-to-weight ratio, flexible, para-aramid modified fiber composites that mitigate corrosion and provide EMI shielding under severe mechanical strain over a temperature range of -145°C to 450°C. Our Kevlar based composites can be formed and seamed to maintain EM immunity in product lengths currently up to 100". These tough materials are offered herein as non-parasitic, cable shielding to improve the RF performance and save several pounds of weight per yard relative to current over-braiding wires, foil wraps, and metal conduit. The EMI SE of Metal Rubber modified Kevlar is equal to that for a 2 mm thick copper plate and nearly double that for an EMI shielding commercial-off-the-shelf (COTS) product over 4 18 GHz. The proposed materials have an areal density of 0.008 g/cm2, resist acids, are nickel and silver-free to mitigate galvanic corrosion, and survive anticipated vibration and mechanical loads associated with standard transport aircraft flight profiles. NanoSonic shall form composite conduit utilizing our HybridSil Anti-Corrosion polymer matrix resins and Metal Rubber modified Kevlar as filled and pre-preg based composites for use as cable shields compatible with both composite and aluminum enclosures for demonstration against narrow and wideband HPM sources. BENEFIT: NanoSonic would primarily develop Metal Rubber modified Kevlar based composites as a super lightweight cable shielding alternative to heavy metal over-braiding, metal foils and other parasitically attached shielding structures. The innovative super lightweight nanocomposites would be primarily transitioned to protect cables within aircraft against harsh EM environments including High Power Microwave (HPM) and Electromagnetic Pulse (EMP). The HPM hardened composite conduit shall be later transitioned to dual use domestic applications in commercial aircraft and specific DoD systems. Metal Rubber Kevlar composites shall serve a broad range of military and civilian applications including avionic and communication systems on board commercial aircraft from personal electronic devices and stray radar energy. Dual-use military applications for various forms of Metal Rubber nanocomposites include highly mechanically robust EMI and radiation shielding appliques. Additional applications include biomimetric systems, thermal control system materials, actuators, lightning strike protection, RF shielding for large area structures and sensors.