Castellated Insulating Insert for Aircraft Fuel Line Lightning Protection
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Solution Overview
Problem
Aircraft fuel systems made from composite materials with low electrical conductivity are prone to electrical discharges during lightning strikes, leading to potential ignition, equipment malfunction, and structural integrity issues due to high current induction and electric arcs.
Innovation Solution
An electrical insulation device with a cylindrical body and castellated crown made of insulating material, attached to metal flanges, is inserted between linear components like pipes to prevent current passage, providing efficient insulation in limited spaces, with a minimum resistance of 100 Mega ohms at 500 VDC and 1000 VDC.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If composite materials are used for fuel tank structures, then weight is reduced, but electrical resistance increases causing induction effects and electrical discharge risks
Solution Approach 1:
The linear metal component is divided into multiple insulated sections by inserting insulating inserts between adjacent metal parts. This segmentation prevents continuous current flow along the component while maintaining the structural integrity and weight benefits of composite fuel tank construction.
Solution Approach 2:
Insulating inserts are introduced as intermediary elements between metal components within the composite fuel tank structure. These inserts act as mediators that block electrical current paths and prevent induction effects while allowing the composite structure to maintain its lightweight characteristics.
2Reliability
If insulating inserts are placed in linear metal devices, then electrical insulation is improved, but space availability is reduced
Solution Approach 1:
The insulating inserts are nested within the existing linear metal components by placing them between adjacent metal sections. This nesting approach allows the insulating elements to be accommodated within the existing structural envelope without requiring additional external space, thus maintaining compact fuel system architecture.
3Strength
If metal flanges are used for component connection, then structural strength is maintained, but electrical conductivity increases creating discharge paths
Solution Approach 1:
The continuous metal structure is segmented by inserting insulating inserts between metal flanges and components. This segmentation maintains the mechanical connection strength through the flange interfaces while simultaneously breaking the electrical conductivity path, preventing discharge propagation along the fuel system components.
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
Effectively prevents electrical discharges and equipment malfunctions by ensuring electrical insulation in fuel and ventilation lines, maintaining structural integrity and preventing ignition, while being applicable to various systems with space constraints.
Implementation Method 1
The part made of insulating material is constituted by a cylindrical body with a castellated crown on its outer side... providing efficient insulation in limited spaces, with a minimum resistance of 100 Mega ohms at 500 VDC and 1000 VDC
Data Source
AI summary
An electrical insulating device for a linear component forming part of a fuel system subjected to risks of possible external electrical discharges formed by a part (13) made of insulating material attached to two metal flanges (15, 17) that allow inserting the device (11) between two parts of said linear component, said part (13) being formed by a cylindrical body (21) with a castellated crown (23) on its outer side, formed by longitudinal (25) and transverse (27) segments, and said metal flanges (15, 17) having transverse projections (31, 33) facing the transverse segments (27) of the castellated crown (23) for facilitating their attachment by suitable means (39).