Conformable Composite Tank for Irregular Aircraft Spaces
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Solution Overview
Problem
Aircraft pressurized tanks made of metal alloys are heavy, requiring more fuel and are not optimally designed to withstand pressure, vibration, and shock stresses, making them inefficient for fuel consumption and space utilization.
Innovation Solution
A conformable tank made from an additively manufactured integral structure of fiber filament reinforced composite material, featuring internal supports like baffles and ribs, which are designed to conform to irregular aircraft spaces and withstand pressure while being lightweight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal tanks with internal bracing are used to withstand pressure and stress, then structural strength is improved, but weight increases
Solution Approach 1:
The patent applies composite materials (fiber-reinforced polymers) to manufacture the tank body, replacing traditional metal alloys. This provides equivalent or superior structural strength while significantly reducing weight, directly resolving the contradiction between strength and weight.
Solution Approach 2:
The patent employs curved and conformable tank geometries instead of flat walls with sharp corners. The curved surfaces naturally distribute stress more evenly, reducing the need for heavy internal bracing while maintaining structural integrity under pressure and vibration loads.
2Reliability
If traditional metal tank manufacturing is used, then structural integrity is ensured, but fuel efficiency deteriorates
Solution Approach 1:
By using lightweight composite materials, the tank weight is reduced, which directly decreases the fuel consumption required to move the aircraft, thereby improving fuel efficiency while maintaining structural integrity through the inherent properties of the composite materials.
Solution Approach 2:
The patent changes the material parameters from dense metal alloys to lighter composite materials with optimized fiber orientations, achieving a better strength-to-weight ratio that improves fuel efficiency without compromising structural integrity.
3Ease of manufacture
If flat walls with sharp corners are used in tank design, then manufacturing simplicity is improved, but stress resistance deteriorates
Solution Approach 1:
The patent replaces flat walls with curved surfaces that eliminate sharp corners. These curved geometries naturally distribute stress more uniformly across the tank surface, significantly improving stress resistance while the additive manufacturing process maintains ease of production for these complex shapes.
4Volume of moving object
If conformable tank design is used to fit irregular aircraft spaces, then space utilization is improved, but manufacturing complexity increases
Solution Approach 1:
The patent utilizes additive manufacturing technology, which fundamentally changes the manufacturing approach from traditional subtractive or formative methods. This enables the production of highly complex, conformable geometries that fit irregular aircraft spaces without proportionally increasing manufacturing complexity, as the additive process naturally handles intricate designs.
Data Source
AI summary
A conformable tank includes a body with a plurality of walls defining a cavity in the body, and an internal support connected to an internal surface of one of the plurality of wall of the body and protruding into the cavity of the body. The body and the internal support are an additively manufactured integral structure formed by a fiber filament reinforced composite material.