Conductive Insert with Projections for Aluminum Bonding
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Solution Overview
Problem
Current methods for providing electrical connections between aluminum components in aircraft, such as cured elastomer gaskets and metallic gaskets, face issues like moisture ingress, galvanic corrosion, and time-consuming application processes, while also requiring inhibitor greases that can crack and fail under vibration and temperature changes.
Innovation Solution
A conductive insert with triangular projections that penetrate sealants and oxides on aluminum surfaces, providing a low resistance bond without the need for gaskets, made from conductive materials like Monel, which can withstand harsh environments and maintain a stable electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If cured elastomer gaskets are used to seal mating surfaces, then moisture ingress is prevented, but the gaskets become bonded under compression and allow moisture between surfaces after temperature cycling
Solution Approach 1:
The patent removes the elastomer gasket material from the sealing system entirely, replacing it with a metallic seal that uses projections to create a metal-to-metal seal. This extraction of the problematic elastomer material eliminates the bonding and memory effects while maintaining sealing capability.
Solution Approach 2:
The patent uses metallic material (aluminum or aluminum alloy) for both the terminal and the seal, creating a homogeneous material system. This eliminates galvanic corrosion issues that arise from dissimilar materials and provides consistent thermal and electrical properties throughout the sealing interface.
2Reliability
If metallic gaskets with sealants are used, then moisture ingress is reduced, but permanent bonding occurs and application/removal becomes time consuming
Solution Approach 1:
The patent eliminates sealants and adhesives from the system, relying solely on the mechanical action of the metallic projections to create the seal. This removal of chemical bonding agents enables rapid installation and removal without permanent bonding.
Solution Approach 2:
The metallic projections self-align and self-seal when compressed between the terminal and mating surface, eliminating the need for precise pre-positioning of sealants or complex application procedures. The seal forms automatically through the compression and rebound action of the projections.
3Reliability
If corrosion resistant compounds and sealants are applied, then corrosion is prevented, but the process becomes time consuming and the compounds crack during structure flexing
Solution Approach 1:
The patent uses aluminum or aluminum alloy for the insert, matching the material composition of the aircraft structure. This material homogeneity provides inherent corrosion resistance without requiring additional protective compounds or sealants, simplifying the system to a single material solution.
4Reliability
If gaskets with dissimilar base materials are used, then sealing is provided, but galvanic corrosion is caused due to electrolyte introduction
Solution Approach 1:
The patent specifies that the insert be made of aluminum or aluminum alloy, matching the material of the aircraft structure and terminal. This material homogeneity eliminates the galvanic series differential, preventing galvanic corrosion while maintaining effective sealing through the metallic projections.
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 insert offers a cost-effective, rapid installation and removal solution with minimal structural damage, eliminating the need for inhibitor greases and ensuring a reliable, low resistance electrical connection under extreme conditions.
Implementation Method 1
the projections being compressible so that the edges of the projections are moveable in a direction which is essentially parallel to a longitudinal axis of the insert
Implementation Method 2
A conductive insert with triangular projections that penetrate sealants and oxides on aluminum surfaces
Implementation Method 3
The conductive insert offers a cost-effective, rapid installation and removal solution with minimal structural damage, eliminating the need for inhibitor greases and ensuring a reliable, low resistance electrical connection under extreme conditions
Data Source
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AI summary
A conductive insert which provides a low resistance bond between low conductive materials. The insert includes a first surface and an oppositely facing second surface. A plurality of openings extends between the first surface and the second surface. At least one first projection extends from the first surface proximate respective first openings, the at least one first projection extending from the first surface in a direction away from the second surface. At least one second projection extends from the second surface proximate respective second openings, the at least one second projection extending from the second surface in a direction away from the first surface. The insert provides a stable, low resistance electrically conductive path between the conductive materials.