Exploiting of Nano Composite Materials Technology for Revolutionary Satellite Development

Due to launch cost of systems that operate in space, engineers look for methods to reduce weight while maintaining technical performance. A key component of the electrical system is the network of cables running throughout a spacecraft. One particular performance parameter that is crucial with respect to electronics of a satellite system is electromagnetic interference (EMI) shielding. To achieve EMI shielding of cables, a shielded conductor is formed by bonding a thin layer of conductive material to the outer surface of the wires. Shielding is necessary to keep the signal from escaping the wire bundle and to keep exterior signals from interfering with the wires. Currently, wires are shielded by metal mesh (aluminum, silver, or copper) that surrounds the conductor, which is a heavy solution. A lighter weight solution is to replace metals with nano-composite materials. In the Phase I program, San Diego Composites (SDC) demonstrated, through fabricating and testing subscale cables, a weight savings of 20% could be achieved using nano-composite materials for shielding. In the Phase II program, SDC proposes to develop a reproducible manufacturing method for nanomaterial shielding in electrical wiring resulting in significant system level weight benefits for satellite systems. Commercialization of the shielding materials can extend to lightweighting electrical systems on aircraft, missiles and ships. BENEFIT: Nanomaterial technology can be used for shielding of electrical systems in spacecraft, missiles, aircraft and ships. The technology is not restricted to a specific program and can be used for a multitude of applications. Using this innovative technology has the potential to decrease weight and cost of cabling and improve EMI shielding throughout every system. With improved shielding capabilities, the amount of shielding required will be reduced, therefore reducing cost and weight. For larger platforms, many miles of shielded cabling can run throughout an entire system and therefore a small reduction in the weight of shielded cables can lead to significant weight reduction. One pound of weight savings can reduce launch cost by $10K. For a large satellite weighing 15 tons, 1/3 of its weight is derived from copper wiring harnesses. The Phase I program showed that by using nanomaterial shielding instead of metal shielding, weight was decreased by 20%. By reducing the cabling weight by 20% in a 15 ton satellite, the launch cost would be reduced by $20M. Additionally, current shielding materials consist of a braided metal and a film, which are assembled in two operations. As such, assembly time and its associated cost can be reduced with the use of nanomaterials because the nanomaterial is one material applied in one step. Due to the nature of the nanomaterials SDC has proposed, shielding coverage could improve because of the continuous nature of the nanomaterials. Along with improved electrical performance due to the nanomaterials, improved thermal capabilities and lightning strike protection are also possible.