Conductive Composite Avionics Rack for High-G Load Mounting
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Solution Overview
Problem
Existing aircraft equipment racks fail to meet airworthiness standards for withstanding high G-forces, temperature fluctuations, and fire resistance while providing a secure and efficient mounting solution for avionics equipment.
Innovation Solution
A modular rack system comprising upper and lower rectangular frames interconnected by electrically conductive carbon fiber composite struts with orthogonal flanges and mounting holes, designed to withstand high G-forces and temperature variations, and featuring a grounding path for avionics equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional metal racks are used to meet FAA strength and fire resistance standards, then structural strength and fire retardancy are improved, but weight increases
Solution Approach 1:
The patent employs carbon fiber reinforced polymer (CFRP) composite materials to construct the rack structure. These composites provide high strength-to-weight ratio, meeting FAA strength requirements while significantly reducing rack weight compared to traditional metal constructions. The composite material inherently provides fire retardancy and corrosion resistance properties required by aviation standards.
2Weight of moving object
If carbon fiber composite struts are used to reduce weight, then weight is reduced, but electrical conductivity for grounding paths is lost
Solution Approach 1:
The patent incorporates electrically conductive elements specifically at strategic locations within the carbon fiber composite structure. Conductive coatings or embedded conductive materials are applied to specific surfaces and interfaces where electrical grounding is required, while the bulk composite material maintains its lightweight properties. This localized approach provides necessary electrical conductivity without compromising the overall weight reduction benefits.
3Adaptability or versatility
If modular design with multiple components is used to improve adaptability, then adaptability and ease of assembly are improved, but device complexity increases
Solution Approach 1:
The patent divides the rack into modular segments including adjustable mounting panels, interchangeable support structures, and standardized connection interfaces. Each module can be independently configured and assembled to meet specific avionics equipment requirements. This segmentation enables adaptability for different equipment types while maintaining manageable complexity through standardized components and assembly procedures.
4Temperature
If traditional metal materials are used to ensure fire retardancy, then fire resistance is improved, but corrosion resistance and weight performance deteriorate
Solution Approach 1:
The carbon fiber reinforced polymer composite material inherently provides both fire retardancy and corrosion resistance properties. The polymer matrix is formulated to be fire-resistant while the carbon fiber reinforcement provides structural integrity. This composite construction eliminates the corrosion issues associated with metal racks while maintaining fire safety standards, and simultaneously reduces weight compared to metal alternatives.
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 modular rack system effectively secures avionics equipment, meets FAA standards for fire retardancy and corrosion resistance, and provides a stable grounding path, ensuring safe operation under extreme conditions.
Implementation Method 1
Each strut is at least partially formed of an electrically conductive carbon fiber composite material... At least one electrically conductive grounding path is created from the avionics equipment, through the rack, to the aircraft
Data Source
AI summary
A modular rack for mounting avionics equipment comprises an upper rectangular frame, a lower rectangular frame, and a plurality of struts interconnecting the upper rectangular frame and the lower rectangular frame. Each strut is at least partially formed of an electrically conductive carbon fiber composite material and includes at least one flange extending substantially orthogonal to the strut. The flange includes a plurality of mounting holes to allow avionics equipment to be mounted to the rack. A method of mounting avionics equipment in an aircraft is also provided.