Reusable Wire Bundle Protectors for Aircraft Wiring
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Solution Overview
Problem
Existing methods for protecting wiring and connectors during fabrication and transport are inefficient, prone to chafing, abrasion, and contamination, and do not effectively address outgassing issues, requiring significant labor and resources, with limited reuse of protective materials.
Innovation Solution
The use of fire retardant wire bundle protectors with self-securing openings and ties to securely cover wire bundle free ends and connectors, made from materials like fire retardant plastics and anti-static fabrics, which can be reused and easily attached to structures, reducing stress and contamination risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective material such as bubble wrap is applied to wiring and wiring connections, then protection from abrasion and chafing is improved, but material, labor and time expenditures increase significantly
Solution Approach 1:
The protective covering is divided into multiple individual sleeves, each designed to fit specific wire bundles or connectors. This segmentation allows for selective application only where protection is needed, reducing overall material usage and installation time while maintaining protection effectiveness.
Solution Approach 2:
The protective sleeves incorporate self-securing features such as elastic bands, snap fasteners, or Velcro closures that automatically secure the covering without requiring additional straps, clips, or complex fastening mechanisms. This self-service capability eliminates the need for separate securing operations, significantly reducing labor and time expenditures.
2Reliability
If protective material is applied to wiring and wiring connections, then protection from abrasion and chafing is improved, but the removal process requires heightened attention and care to avoid damaging wires and wire connectors
Solution Approach 1:
The protective sleeves utilize dynamic fastening mechanisms such as elastic bands that can be easily stretched for installation and relaxation for removal, or snap fasteners that provide audible feedback for proper engagement and easy disengagement. These dynamic features allow for quick, tool-free removal without requiring careful manual manipulation, thereby improving ease of operation during removal while maintaining protection during transport.
3Reliability
If protective material is applied to wiring and wiring connections, then protection from contamination is improved, but it is difficult to recapture the protective material for reuse
Solution Approach 1:
The protective sleeves are designed as reusable components that can be easily removed, cleaned, and reinstalled on the same or different wire bundles. The modular sleeve design with standardized sizes allows for recapture and redistribution of protective coverings across multiple connection points, significantly reducing material waste and enabling economical reuse throughout the assembly process and during maintenance operations.
4Reliability
If traditional protective materials are used, then protection from physical damage is provided, but outgassing from plastic materials may be detrimental to the performance of electrical contacts and electrical connectors
Solution Approach 1:
The protective covering material is selected and formulated with specific parameters optimized for aerospace environments, including low outgassing properties, flame retardancy, and appropriate tensile strength. By changing the material parameters from conventional plastics to aerospace-grade materials, the solution maintains physical protection capabilities while eliminating the harmful outgassing effect that would compromise electrical connector performance.
Solution Approach 2:
The protective sleeves utilize composite material construction combining flame-retardant polymers with low-outgassing additives and reinforcing fibers. This composite approach integrates multiple functional properties: physical protection from abrasion, flame resistance for safety, and minimal outgassing to protect electrical contacts. The composite material structure achieves synergistic performance that single materials cannot provide alone.
Data Source
AI summary
An unassembled aircraft segment that has a plurality of wire bundles is disclosed herein. Each of the plurality of wire bundles comprises at least one of (a) a free end, and (b) a connector. The unassembled aircraft segment also has a plurality of wire bundle protectors each having a fire retardant material, an outer surface, an inner surface configured to define an interior portion, a self-securing opening configured to provide access to the interior portion, and at least one tie connected to the outer surface and configured to secure each of the plurality of wire bundle protectors to a structure of the unassembled aircraft segment. Each of the plurality of wire bundle protectors is installed on each free end and each connector of the plurality of wire bundles.