Intersecting Conducting Strips for Aircraft Current Return Network
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The use of composite materials in aircraft fuselage structures, which have poor electrical conductivity, hampers the formation of a current return network, leading to inefficient and costly manual metallization processes for achieving electrical continuity, resulting in imperfections, increased production and maintenance cycles, and potential premature fatigue due to trapped mastic or paint.
Innovation Solution
A current return network element comprising electrically conducting strips made from a single piece, intersecting to form natural electrical and structural junctions without the need for add-on means, eliminating the risk of connection degradation and reducing production and maintenance costs by eliminating the need for manual metallization operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used for fuselage structure to achieve mass saving, then weight is reduced, but electrical conductivity deteriorates
Solution Approach 1:
The current return network is segmented into multiple conducting strips arranged in a grid pattern, allowing the network to function effectively even when individual strips are interrupted by composite structure joints or openings
Solution Approach 2:
A dedicated conducting strip network is introduced as an intermediary element between the composite fuselage structure and the electrical equipment, providing a reliable current return path independent of the composite material's poor conductivity
2Reliability
If manual metallisation operation is performed to achieve electrical continuity, then electrical junction is formed, but manufacturing precision deteriorates due to trapped mastic or paint
Solution Approach 1:
The conducting strips are pre-installed and fixed to the fuselage structure before final assembly, ensuring proper positioning and eliminating the need for post-assembly metallisation operations
Solution Approach 2:
The problematic manual metallisation step is completely removed from the process by using pre-fabricated conducting strips that make direct contact with prepared surfaces, eliminating sources of contamination
3Reliability
If add-on junction means are used to make structural and electrical junctions, then electrical continuity is achieved, but device complexity increases
Solution Approach 1:
The conducting strips serve dual purposes: they provide both structural support and electrical continuity, eliminating the need for separate junction means and reducing overall system complexity
Solution Approach 2:
The conducting strip network performs multiple functions simultaneously: current return, structural reinforcement, and mechanical attachment, replacing multiple specialized components with a single multi-functional element
4Reliability
If manual metallisation operation is performed for each junction means, then electrical continuity is achieved, but productivity decreases
Solution Approach 1:
The conducting strips are pre-fabricated and pre-positioned during the main assembly process, eliminating time-consuming post-assembly metallisation operations for each junction
Solution Approach 2:
The lengthy manual metallisation process is completely bypassed by using conducting strips that make direct electrical contact through mechanical fastening alone
5Strength
If intermediate mastic is used at structural junctions to prevent wear, then mechanical protection is improved, but electrical conductivity deteriorates
Solution Approach 1:
The intermediate mastic layer is completely removed from the electrical contact interface by using conducting strips that contact the metal surface directly at designated attachment points
Solution Approach 2:
The conducting strips make contact with the metal structure at specific localized points where electrical continuity is needed, while allowing mastic to be present in non-critical areas for wear protection
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution provides a reliable, low-maintenance current return network with improved electrical conductivity and mechanical resistance, reducing production and maintenance cycles while adapting to various aircraft geometries, thus enhancing the structural and electrical integrity of the aircraft.
Implementation Method 1
a current return network element for an aircraft comprising a plurality of electrically conducting strips intersecting each other and made from a single piece
Data Source
AI summary
A current return network element for aircraft particularly with high conductivity. The purpose is achieved by using a plurality of electrically conducting strips intersecting each other and made from a single piece, at a spacing from each other so as to form a plurality of openings between them.