Airframe Coupling Structure Lightning Protection
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Solution Overview
Problem
Existing coupling structures for aircraft wing surface panels are inadequate in preventing electric arcs during lightning strikes, as they rely on precise interference fits and sealants, which can fail due to processing errors or impaired electrical conduction, leading to insufficient lightning protection, especially in fuel tank environments.
Innovation Solution
A coupling structure featuring a conductive area formed of conductive material and an insulating area formed of insulating material, where the conductive area allows electrical conduction between wing surface panels and the insulating area suppresses lightning current flow near the inner side of the airframe, enhancing the tolerance to lightning strikes and combining with other arc suppression and sealing means for reliable protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If interference fit or transition fit is used to prevent gaps between fastener member and through-holes, then manufacturing precision is improved, but device complexity increases and reliability decreases due to sensitivity to processing errors
Solution Approach 1:
The invention applies different surface treatments to different regions of the wing surface panel. A conductive area is created at the through-hole location to ensure electrical conduction for lightning protection, while an insulating area is formed at the end part to prevent electric arc generation. This local differentiation resolves the contradiction by ensuring both gap prevention and reliable lightning protection without requiring precise interference fit throughout the entire fastener assembly.
Solution Approach 2:
The invention uses composite surface treatment combining conductive and insulating materials on the same wing surface panel. The conductive area (e.g., conductive paint or plating) and insulating area (e.g., insulating paint or coating) are applied to different regions, creating a composite structure that simultaneously addresses electrical conduction needs for lightning protection and arc suppression requirements, thereby improving reliability without increasing device complexity.
2Reliability
If sealant is used to cover the leading end part of fastener member, then lightning protection is improved, but manufacturing complexity increases and reliability decreases due to potential sealant failure
Solution Approach 1:
The invention extracts the lightning protection function from the sealant and assigns it to the conductive area formed on the wing surface panel. The sealant's role is reduced to only sealing the through-hole gap, while the conductive area handles electrical conduction for lightning protection. This separation of functions reduces device complexity and eliminates the reliability issue of sealant-based lightning protection.
Solution Approach 2:
The conductive area acts as an intermediary between the fastener member and the wing surface panel, providing a dedicated pathway for lightning current dissipation. This intermediary structure ensures reliable electrical conduction without relying on sealant integrity, thereby improving lightning protection reliability while reducing overall device complexity.
3Reliability
If cap with insulating material is used to fill the gap between cap and fastener member, then lightning protection is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention merges the insulating function into the wing surface panel itself by forming an insulating area directly on the panel surface at the end part. This eliminates the need for a separate cap structure with insulating material, as the insulating area on the panel provides the same arc suppression function. The merging reduces device complexity and manufacturing cost while maintaining electric arc suppression reliability.
Solution Approach 2:
The wing surface panel is given multiple functions: structural support, lightning current dissipation through the conductive area, and electric arc suppression through the insulating area. By making the panel multi-functional, the invention eliminates the need for separate cap and insulating material components, thereby reducing device complexity and manufacturing cost while maintaining all necessary protection functions.
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
The conductive and insulating areas effectively suppress electric arcs within the wing, ensuring sufficient lightning protection and reliability, even if individual suppression means fail, by directing lightning currents away from critical internal spaces and maintaining the integrity of fuel tank environments.
Implementation Method 1
a conductive area that is formed of a conductive material in a given part of a portion in which the plurality of members are opposed to each other
Implementation Method 2
an insulating area that is formed of an insulating material in a portion other than the given part of the portion in which the plurality of members are opposed to each other
Data Source
AI summary
Provided is a coupling structure for airframe components that is capable of ensuring sufficient lightning protection capability. A conductive pattern part 40 made of a conductive material is formed around each fastener member 24 between wing surface panels 21A and 21B. The conductive pattern part 40 is formed, for example, around each of holes 21c and 21d on the plane on which the wing surface panel 21A and the wing surface panel 21B abut against each other. Then, the conductive pattern part 40 is pushed against both the wing surface panel 21A and the wing surface panel 21B by the fastening power of the fastener members 24, whereby electrical conduction between the wing surface panel 21A and the wing surface panel 21B can be achieved.