Composite Tube With Embedded Stranded Wire for Stable Fuel Gauging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fuel gauging systems in aircraft face challenges in achieving a reliable and low-resistance electrical connection between carbon-fiber composite tubes and stranded wires, which affects the accuracy and efficiency of fuel measurement.
Innovation Solution
A composite tube with an embedded stranded wire is formed using a method involving a core, electrically conductive layers applied in a cross-ply and helical fashion, and a bagging layer to ensure secure embedding and low resistance connection, followed by curing to create a durable and efficient electrical interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional connection methods (rivets, screws, adhesives) are used to connect stranded wire to composite tube, then mechanical connection is achieved, but electrical connection reliability and low resistance are compromised
Solution Approach 1:
The patent merges the mechanical connection and electrical connection functions into a single integrated structure. The stranded wire is embedded within the composite tube wall, creating simultaneous mechanical anchoring and electrical contact without requiring separate connection components. This eliminates the need for rivets, screws, or adhesives while achieving both mechanical strength and electrical conductivity.
Solution Approach 2:
The patent uses a composite tube structure with conductive layers integrated into the wall. The tube wall comprises multiple layers including at least one electrically conductive layer that provides the electrical connection pathway. This composite structure combines mechanical structural integrity with electrical conductivity in a single integrated component.
2Manufacturing precision
If traditional connection methods are used, then assembly is simplified, but manufacturing precision and connection consistency are compromised
Solution Approach 1:
The stranded wire is positioned and embedded within the composite tube wall during the tube manufacturing process itself, before the tube is completed. This preliminary placement ensures consistent positioning and connection quality throughout production, as the wire is integrated into the tube structure during formation rather than attached afterward.
Solution Approach 2:
The stranded wire is nested within the composite tube wall structure. The wire is positioned between layers of the composite tube, with the conductive layers providing both structural and electrical functions. This nesting approach ensures precise positioning and consistent electrical contact while maintaining manufacturing efficiency.
3Reliability
If stranded wire is embedded in composite tube, then electrical connection is improved, but manufacturing process complexity increases
Solution Approach 1:
The composite tube wall layers serve multiple functions simultaneously: structural support, electrical insulation where needed, and electrical conduction where required. The conductive layers within the tube wall provide both mechanical reinforcement and electrical connection pathways, eliminating the need for separate dedicated electrical connection components and simplifying the overall manufacturing process.
Data Source
Figure 1~2
Figure 1A
Figure 3~5
AI summary
The present disclosure includes a composite tube with a stranded wire and a method for making same. The method may include providing a core and providing at least one layer comprising electrically conductive material. The method may further include applying the at least one layer around at least a portion of the core. The method may further include providing the stranded wire comprising an embedded portion. The method may further include embedding the embedded portion of the stranded wire within the at least one layer of electrically conductive material.